MUNICIPAL CORPORATION OF GREATER MUMBAI BRIDGE DEPARTMENT TECHNICAL SPECIFICATIONS 2013

MUNICIPAL CORPORATION OF
GREATER MUMBAI
BRIDGE DEPARTMENT
VOLUME-II
TECHNICAL SPECIFICATIONS FOR
BRIDGE WORKS
2013
BRIDGES SCHEDULE 2013
Foreword
Ever since establishment of Bombay Municipal Corporation (now Municipal Corporation of Greater
Mumbai) in 1888 by the erstwhile British rulers in India, in the last 125 years of the history of its
existence MCGM has catered to every aspect of the citizen of Mumbai that can be conceived of.
Look to heritage buildings like Victoria Terminus (Chhatrapati Shivaji Terminus), Office of Municipal
Corporation, Dadabai Naoroji Road, Dr. Babasaheb Ambedkar Road, Marine Drive (Netaji Subhash
Road), Prince of Wales Museum, Gateway of India, Malabar Hill Reservoir, Nair Hospital, Lokmanya
Tilak Hospital, KEM Hospital etc which are the service centers for the citizens. Municipal Services
have also been provided in the suburban and extended suburban areas merged in 1950 & 1957
respectively. The obligatory duties are performed well but still there is need to improve in quantity
and quality of services to be provided to the citizens.
Ethical governance and righteous work culture will certainly bring positive changes in design and
implementation of projects. One may take an example of the first Municipal Head Quarter Building,
that was completed in year 1893, in four years, designed by F W Stevens and the execution part
was dealt by Project Engineer Shri Rao Saheb Sitaram Khanderrao Vaidya, who executed the
project of 77.70m high structure and saved Rs.68,000/- as against estimated cost of Rs. 11.80
Lakhs.
The need is to work with precision and accuracy. There shall be harmony between planning and
execution so as to evolve best economics with focused goals.
MCGM is one of the largest local self governments in the Asian Continent. In observance of historic
traditions of strong civic activism, with the change in time and living conditions to match with the
urbanization, MCGM has focused in providing variety of engineering services viz, storm water drain,
sewerage, water supply, roads, bridges, solid waste management, environmental services. Beside
this, the Corporation is also providing dedicated services in the Health sector by establishing Major
and Peripheral hospitals.
To update and modernize the mechanism being used for working on related projects from the stage
of conceptualization to execution, the need was realized to revise prevailing “Schedule Of Rates”
along with specifications which were in operation with various departments and being prepared
individually as per their need and revised at different span of time, resulting into various anomalies.
To overcome all these, it was essential to revise the schedule of rates, not only with simple
mechanized revision but incorporating major changes to keep up with the pace of urbanization,
civilization, construction techniques / mechanization and voluminous developments by restructuring
Municipal Corporation of Greater Mumbai

items in the schedule to cover all requirements. This exercise would provide comfort with designs
and field necessities and will assist in effective checks on creation of extra items during execution.
A conscious decision has been taken to prepare Unified Schedule of Rates to keep pace with the
changing time; a first step forward in this direction. Since long time, there have been demands made
by the stake holders like Municipal Engineers and Contractors to remove non-uniformity, anomalies
and discrepancies in various schedules of rates for work contracts of various departments of MCGM.
Every department had its own expertise and way of functioning which got reflected in its independent
schedule of rates, which however, had no linkage with the fair market rates and schedules of other
departments, resulting into extra items and fair rates. In place of earlier 9 Schedule Of Rates, the
Unified Schedule of Rates is an effort and seeks to rectify the defects, discrepancies and non
uniformities which will provide ease and accuracy of estimation to the Engineers.
In view of the enormous and voluminous nature of work, keeping time frame in perspective and
above all, to ensure professionalism, the work of preparation of Unified Schedule of Rates (USR)
was awarded to the eminent consultants M/s. TATA Consulting Engineers Ltd. M/s. TATA Consulting
Engineers Ltd were directed to conduct a integrated factual market research for major materials from
stockists/manufacturers/dealers and to study schedules of rates of Govt. bodies like C.P.W.D.,
P.W.D. etc The new Rate Analysis are based on Factual Market research done by M/s.TATA
Consulting Engineers Ltd.
The anomalies in rate are minimized after extensive market research and collection of quotations
from reputed large scale stockists/dealers, and also after comparison with rates of CPWD, PWD etc.
The Unified Scheduled of Rates is linked with its comprehensive specifications of basic important
activities so as to have clarity in execution. These specifications follow a chronology of general
scope of the item, material required, processing of material, construction operation, finishing and
mode of measurement. Rigid Standard Operating Procedures (SOPs) and complete control on
processes will certainly satisfy quality parameter. The need for checking the quality of construction is
quite apparent and shall be ensured throughout the construction process. To achieve this, the
Unified Scheduled of Rates incorporates quality assurance procedures.
All the rates are also linked to their detailed specifications and wherever required, with drawings.
Though there are about 12500 items, every item is now given a Unique Code No. which will
eliminate the repetition.
It has been our endeavor to include all the necessary modern materials and technologies in Unified
Schedule of Rates, for example, the concept of green building, which will go a long way to have
control on creation of extra items and fair rates. A salient feature of this Unified Schedule of Rates is
'Starring of items' specified categorically which can be used only at certain works or locations.

Another salient feature is 'Dynamic Rate System' which will be based on study of data base of
quantities and bidding prices of awarded contracts on the basis of which necessary corrections can
be applied to the Unified Schedule of Rates at specified intervals. The MCGM will be now be in a
position to revise the Unified Scheduled of Rates every year, after incumbency period of M/s.TATA
Consulting Engineers Ltd of one year, to work with and correct the system as and when necessary.
I am sure that this 'Unified Scheduled of Rates' will be a milestone in civic governance by MCGM.
This publication shall be of great help and guidance to the officers engaged in the project work of
MCGM.
A.M.C. (Project) Municipal Commissioner

SPECIFICATIONS FOR CONSTRUCTION OF BRIDGES SP-BW
INDEX
SP-BW CLAUSE TITLE PAGE NO.
1000 MATERIAL FOR STRUCTURES ............................................................................ 9
1001 GENERAL ............................................................................................................ 10
1002 SOURCES OF MATERIAL ................................................................................... 10
1003 BRICKS ................................................................................................................ 10
1004 STONES ............................................................................................................... 10
1005 CAST IRON .......................................................................................................... 11
1006 CEMENT .............................................................................................................. 11
1007 COARSE AGGREGATES ..................................................................................... 12
1008 SAND/FINE AGGREGATES ................................................................................. 13
1009 STEEL .................................................................................................................. 14
1010 WATER................................................................................................................. 17
1011 TIMBER ................................................................................................................ 18
1012 CONCRETE ADMIXTURES ................................................................................. 18
1013 REINFORCED CONCRETE PIPES ...................................................................... 19
1014 STORAGE OF MATERIALS ................................................................................. 20
1015 TESTS AND STANDARD OF ACCEPTANCE ...................................................... 22
1100 PILE FOUNDATIONS ........................................................................................... 25
1101 DESCRIPTION ..................................................................................................... 26
1102 SUB-SURFACE INVESTIGATION ........................................................................ 26
1103 TYPE OF PILES ................................................................................................... 27
1104 MATERIALS ......................................................................................................... 27
1105 TEST PILES ......................................................................................................... 28
1106 PRECAST CONCRETE PILES ............................................................................. 29
1107 CAST-IN-SITU CONCRETE PILES ...................................................................... 31
1108 STEEL PILES ....................................................................................................... 34
1109 TIMBER PILES ..................................................................................................... 35
MUNICIPAL CORPORATION OF GREATER MUMBAI Page 1

1110 DRIVING EQUIPMENT ......................................................................................... 35
1111 DRIVING............................................................................................................... 36
1112 RAKER (INCLINED) PILES .................................................................................. 40
1113 PILE TESTS ......................................................................................................... 40
1114 PILE CAP ............................................................................................................. 41
1115 IMPORTANT CONSIDERATIONS, INSPECTION/PRECAUTIONS FOR

DIFFERENT TYPES OF PILES .......................................................................................... 42
1116 TOLERANCES ..................................................................................................... 44
1117 TESTS AND STANDARDS OF ACCEPTANCE .................................................... 45
1118 MEASUREMENTS FOR PAYMENT ..................................................................... 45
1200 WELL FOUNDATIONS ......................................................................................... 46
1201 DESCRIPTION ..................................................................................................... 47
1202 GENERAL ............................................................................................................ 47
1203 SETTING OUT AND PREPARATIONS FOR SINKING ......................................... 48
1204 CUTTING EDGE ................................................................................................... 51
1205 Well CURB............................................................................................................ 51
1206 WELL STEINING .................................................................................................. 51
1207 WELL SINKING .................................................................................................... 52
1208 BOTTOM PLUG .................................................................................................... 62
1209 SAND FILLING ..................................................................................................... 63
1210 TOP PLUG ........................................................................................................... 63
1211 WELL CAP ........................................................................................................... 63
1212 TOLERANCES ..................................................................................................... 64
1213 TESTS AND STANDARDS OF ACCEPTANCE .................................................... 64
1215 RATE .................................................................................................................... 65
1300 BRICK MASONRY ................................................................................................ 67
1301 DESCRIPTION ..................................................................................................... 68

1302 MATERIALS ......................................................................................................... 68
1303 PERSONNEL........................................................................................................ 68
1304 CEMENT MORTAR .............................................................................................. 68
1305 SOAKING OF BRICKS ......................................................................................... 69
1306 JOINTS ................................................................................................................. 69
1307 LAYING ................................................................................................................ 69
1308 JOINTING OLD AND NEW WORK ....................................................................... 70
1309 CURING ............................................................................................................... 70
1310 SCAFFOLDING .................................................................................................... 71
1311 EQUIPMENT ........................................................................................................ 71
1312 FINISHING OF SURFACES ................................................................................. 71
1313 ARCHITECTURAL COPING FOR WING/RETURN/PARAPET WALL .................. 73
1314 ACCEPTANCE OF WORK ................................................................................... 73
1316 RATE .................................................................................................................... 74
1400 STONE MASONRY .............................................................................................. 75
1401 DESCRIPTION ..................................................................................................... 76
1402 MATERIALS ......................................................................................................... 76
1403 PERSONNEL........................................................................................................ 76
1404 TYPE OF MASONRY ........................................................................................... 76
1405 CONSTRUCTION OPERATIONS ......................................................................... 76
1406 ARCHITECTURAL COPING FOR WING/RETURN/ PARAPET WALLS ............... 83
1407 TESTS AND STANDARD OF ACCEPTANCE ...................................................... 83
1500 Form Work ............................................................................................................ 84
1501 DESCRIPTION ..................................................................................................... 85
1502 MATERIALS ......................................................................................................... 85
1503 DESIGN OF FORMWORK .................................................................................... 90

1504 WORKMANSHIP .................................................................................................. 90
1505 FORMED SURFACE AND FINISH ....................................................................... 92
1506 PRECAUTIONS .................................................................................................... 92
1507 PREPARATION OF FORMWORK BEFORE CONCRETING ................................ 93
1508 REMOVAL OF FORMWORK ................................................................................ 94
1509 RE-USE OF FORMWORK .................................................................................... 94
1510 SPECIALIED FORMWORK .................................................................................. 95
1511 TEST AND STANDARDS OF ACCEPTANCE ...................................................... 95
1512 MEASUREMENT FOR PAYMENT ....................................................................... 95
1513 RATE .................................................................................................................... 96
1600 Steel Reinforcement (Untensioned) ...................................................................... 97
1601 DESCRIPTION ..................................................................................................... 98
1602 GENERAL ............................................................................................................ 98
1603 PROTECTION OF REINFORCEMENT ................................................................. 98
1604 BENDING OF REINFORCEMENT ........................................................................ 98
1605 PLACING OF REINFORCEMENT ........................................................................ 99
1606 BAR SPLICES .................................................................................................... 100
1607 TESTING AND ACCEPTANCE........................................................................... 102
1608 MEASUREMENTS FOR PAYMENT ................................................................... 103
1609 RATE .................................................................................................................. 103
1700 Structural Concrete ............................................................................................. 104
1701 DESCRIPTION ................................................................................................... 105
1702 MATERIALS ....................................................................................................... 105
1703 GRADES OF CONCRETE .................................................................................. 105
1704 PROPORTIONING OF CONCETRE ................................................................... 107
1705 ADMIXTURES .................................................................................................... 112
1706 SIZE OF COARSE AGGREGATE ...................................................................... 112
1707 EQUIPMENT ...................................................................................................... 113

1708 MIXING CONCRETE .......................................................................................... 114
1709 TRANSPORTING, PLACING AND COMPACTION OF CONCRETE .................. 114
1710 CONSTRUCTION JOINTS ................................................................................. 116
1711 CONCRETING UNDER WATER ........................................................................ 116
1712 ADVERSE WEATHER CONDITIONS ................................................................. 117
1713 PROTECTION AND CURING ............................................................................. 118
1714 FINISHING.......................................................................................................... 120
1715 TOLERANCES ................................................................................................... 121
1716 TESTS AND STANDARDS OF ACCEPTANCE .................................................. 121
1717 MEASUREMENT FOR PAYMENT ..................................................................... 124
1718 RATE .................................................................................................................. 124
1800 Prestressing ........................................................................................................ 125
1801 DESCRIPTION ................................................................................................... 126
1802 MATERIALS ....................................................................................................... 126
1803 TESTING OF PRESTRESSING STEEL AND ANCHORAGES ........................... 128
1804 WORKMANSHIP ................................................................................................ 128
1805 SUPERVISION ................................................................................................... 132
1806 TENSIONING EQUIPMENT ............................................................................... 132
1807 POST-TENSIONING........................................................................................... 133
1808 1808. GROUTING OF PRESTRESSED TENDONS ........................................... 134
1809 PRE-TENSIONING ............................................................................................. 134
1810 SAFETY PRECAUTIONS DURING TENSIONING ............................................. 137
1811 TRANSPORTATION AND STORAGE OF UNITS ............................................... 138
1812 TOLERANCES ................................................................................................... 138
1815 RATE .................................................................................................................. 139
1900 Structural Steel ................................................................................................... 141

1901 DESCRIPTION ................................................................................................... 142
1902 GENERAL .......................................................................................................... 142
1903 MATERIALS ....................................................................................................... 142
1904 FABRICATION.................................................................................................... 145
1905 ERECTION ......................................................................................................... 160
1906 PAINTING ........................................................................................................... 170
1909 RATE .................................................................................................................. 178
2000 Bearings ............................................................................................................. 180
2001 DESCRIPTION ................................................................................................... 181
2002 GENERAL .......................................................................................................... 181
2003 STEEL BEARINGS ............................................................................................. 182
2004 SPECIAL BEARINGS ......................................................................................... 187
2005 ELASTOMERIC BEARINGS ............................................................................... 190
2006 POT BEARINGS ................................................................................................. 204
2007 INSPECTION AND TESTING ............................................................................. 211
2010 RATE .................................................................................................................. 212
2100 Open Foundations .............................................................................................. 213
2101 DESCRIPTION ................................................................................................... 214
2102 MATERIALS ....................................................................................................... 214
2103 GENERAL .......................................................................................................... 214
2104 WORKMANSHIP ................................................................................................ 214
2106 TOLERANCES ................................................................................................... 217

2108 RATE .................................................................................................................. 217
2200 Sub-Structure...................................................................................................... 218
2201 DESCRIPTION ................................................................................................... 219
2202 MATERIALS ....................................................................................................... 219
2203 GENERAL .......................................................................................................... 219
2204 PIERS AND ABUTMENTS.................................................................................. 219
2205 PIER CAP AND ABUTMENT CAP ...................................................................... 220
2206 DIRT/ BALLAST WALL, RETURN WALL AND WING WALL .............................. 221
2208 TOLERANCES IN CONCRETE ELEMENTS ...................................................... 221
2210 RATE .................................................................................................................. 222
2300 Concrete Superstructure ..................................................................................... 223
2301 DESCRIPTION ................................................................................................... 224
2302 MATERIALS ....................................................................................................... 224
2303 GENERAL .......................................................................................................... 224
2304 REINFORCED CONCRETE CONSTRUCTION .................................................. 225
2305 PRESTRESSED CONCRETE CONSTRUCTION ............................................... 225
2306 TOLERANCES ................................................................................................... 227
2400 Expansion Joints ................................................................................................. 229
2401 DESCRIPTION ................................................................................................... 230
2402 GENERAL .......................................................................................................... 230
2403 REQUIREMENTS ............................................................................................... 245
2404 STEEL PLATE SLIDING EXPANSION JOINTS .................................................. 246
2405 FILLER JOINTS .................................................................................................. 247
2406 ELASTOMERIC SLAB SEAL EXPANSION JOINT. ............................................ 248

2407 SINGLE STRIP BOX SEAL EXPANSION JOINT ................................................ 254
2410 RATE .................................................................................................................. 262
2411 Asphaltic Plug Joint............................................................................................. 262
2412 Compression Seal Joint ...................................................................................... 265
2413 Modular Strip/Box Seal Expansion Joints ............................................................ 267
2414 Finger Joints ....................................................................................................... 270
2415 TESTING AND ACCEPTANCE STANDARDS .................................................... 271
2416 Pre-installation Criteria ........................................................................................ 273
2500 Pipe Culverts ...................................................................................................... 277
2501 SCOPE ............................................................................................................... 278
2502 MATERIALS ....................................................................................................... 278
2503 EXCAVATION FOR PIPE ................................................................................... 278
2504 BEDDING FOR PIPE .......................................................................................... 279
2505 LAYING OF PIPE................................................................................................ 279
2506 JOINTING ........................................................................................................... 280
2507 BACKFILLING .................................................................................................... 281
2508 HEADWALLS AND OTHER ANCILLARY WORKS ............................................. 281
2509 OPENING TO TRAFFIC ..................................................................................... 281
2511 RATE .................................................................................................................. 281
2600 Appendices ......................................................................................................... 283

1000 MATERIAL FOR STRUCTURES

1001 GENERAL
Materials to be used in the work shall conform to the specifications mentioned on

the drawings, the requirements laid down in this section and specifications for
relevant items of work covered under these specifications.
If any material, not covered in these specifications, is required to be used in the

work, it shall conform to relevant Indian Standards, if there are any, or to the
requirements specified by the Engineer.
1002 SOURCES OF MATERIAL
The Contractor shall notify the- Engineer of his proposed sources of materials
prior to delivery. If it is found after trial that sources of supply previously approved
do not produce uniform and satisfactory products, or if the product from any other
source proves unacceptable at any time, the Contractor shall furnish acceptable
material from other sources at his own expense.
1003 BRICKS
Burnt clay bricks shall conform to the requirements of IS: 1077, except that the
minimum compressive strength when tested flat shall not be less than 8.4 MPa
for individual bricks and 10.5 MPa for average of 5 specimens. They shall be free
from cracks and flaws and nodules of free lime. The brick shall have smooth
rectangular faces with sharp comers and emit a clear ringing sound when struck.
The size may be according to local practice with a tolerance of ± 5 per cent.
1004 STONES
Stones shall be of the type specified. It shall be hard, sound, free from cracks,
decay and weathering and shall be freshly quarried from an approved quarry.
Stone with round surface shall not be used.
The stones, when immersed in water for 24 hours, shall not absorb water by
more than 5 per cent of their dry weight when tested in accordance with IS: 1124.
The length of stones shall not exceed 3 times its height nor shall they be less
than twice its height plus one joint. No stone shall be less in width than the height
and width on the base shall not be greater than three-fourth of the thickness of
the wall nor less than 150 mm.

1005 CAST IRON
Cast iron shall conform to IS:210. The grade number of the material shall not be
less than 14.
1006 CEMENT
Cement to be used in the works shall be any of the following types with the prior
approval of the Engineer:
a) Ordinary Portland Cement, 33 Grade, conforming to IS:269.
b) Rapid Hardening Portland Cement, conforming to IS:8041.
c) Ordinary Portland Cement, 43 Grade, conforming to IS:8112.
d) Ordinary Portland Cement, 53 Grade, conforming to IS:12269.
e) Sulphate Resistant Portland Cement, conforming to IS:12330.
Cement conforming to IS:269 shall be used only after ensuring that the minimum
required design strength can be achieved without exceeding the maximum
permissible cement content of 540 kg/cu.m. of concrete.
Cement conforming to IS:8112 and IS:12269 may be used provided the minimum
cement content mentioned elsewhere from durability considerations is not
reduced. From strength considerations, these cements shall be used with a
certain caution as high early strengths of cement in the 1 to 28-day range can be
achieved by finer grinding and higher constituent ratio of C3S/C2S, where C3S is
Tricalcium Silicate and C2S is Dicalcium Silicate. In such cements, the further
growth of strength beyond say 4 weeks may be much lower than that traditionally
expected. Therefore, further strength tests shall be carried out for 56 and 90 days
to fine tune the mix design from strength considerations.
Cement conforming to IS: 12330 shall be used when sodium sulphate and
magnesium sulphate are present in large enough concentration to be aggressive
to concrete. The recommended threshold values as per IS:456 are sulphate
concentration in excess of 0.2 per cent in soil substrata or 300 ppm (0.03per
cent) in ground water. Tests to confirm actual values of sulphate concentration
are essential when the structure is located near the sea coast, chemical factories,
agricultural land using chemical fertilizers and sites where there are effluent
discharges or where soluble sulphate bearing ground water level is high. Cement
conforming to IS: 12330 shall be carefully selected from strength considerations
to ensure that the minimum required design strength can be achieved without

exceeding the maximum permissible cement content of 540 kg/ cu.m. of

concrete.
Cement conforming to IS:8041 shall be used only for precast concrete products
after specific approval of the Engineer.
Total chloride content in cement shall in no case exceed 0.05 per cent by mass of
cement Also, total sulphur content calculated as sulphuric anhydride (S03) shall
in no case exceed 2.5 per cent and 3.0 per cent when tri-calcium aluminate per
cent by mass is upto 5 or greater than 5 respectively.
1007 COARSE AGGREGATES
For plain and reinforced cement concrete (PCC and RCC) or prestressed
concrete (PSC) works, coarse aggregate shall consist of clean, hard, strong,
dense, non-porous and durable pieces of crushed stone, crushed gravel, natural
gravel or a suitable combination thereof or other approved inert material. They
shall not consist pieces of disintegrated stones, soft, flaky, elongated particles,
salt, alkali, vegetable matter or other deleterious materials in such quantities as to
reduce the strength and durability of the concrete, or to attack the steel
reinforcement. Coarse aggregate having positive alkali-silica reaction shall not be
used. All coarse aggregates shall conform to IS:383 and tests for conformity shall
be carried out as per IS:2386v Parts I to VIII.
The contractor shall submit for the approval of the Engineer, the entire
information indicated in Appendix A of IS:383.
Maximum nominal size of coarse aggregate for various structural components in

PCC, RCC or P5C, shall conform to Section 1700.
The maximum value for flakiness index for coarse aggregate shall not exceed 35
per cent The coarse aggregate shall satisfy the following requirements of grading:
TABLE 1000-1 REQUIREMENTS OF COARSE AGGREGATE
IS Sieve Per cent by Weight Passing the Sieve

Size 40mm 20mm 12.5mm
63mm 100 - -
40mm 95-100 100 -
20mm 30-70 95-100 100
12.5 mm - - 90-100

IS Sieve Per cent by Weight Passing the Sieve

Size 40mm 20mm 12.5mm
10mm 10-35 25-55 40-85
4.75 mm 0-5 0-10 0-10
1008 SAND/FINE AGGREGATES
For masonry work, sand shall conform to the requirements of IS:2116.For plain
and reinforced cement concrete (PCC and RCC) or prestressed concrete (PSC)
works, fine aggregate shall consist of clean, hard, strong and durable pieces of
crushed stone, crushed gravel, or a suitable combination of natural sand, crushed
stone or gravel. They shall not contain dust, lumps, soft or flaky, materials, mica
or other deleterious materials in such quantities as to reduce the strength and
durability of the concrete, or to attack the embedded steel. Motorised sand
washing machines should be used to remove impurities from sand. Fine
aggregate having positive alkali-silica reaction shall not be used. All fine
aggregates shall conform to IS:383 and tests for conformity shall be carried out
as per IS:2386, (Parts 1 to VIII). The Contractor shall submit to the Engineer the
entire information indicated in
Appendix A of IS:383. The fineness modulus of fine aggregate shall neither be

less than 2.0 nor greater than 3.5.
Sand/fine aggregate for structural concrete shall conform to the following grading
requirements:
TABLE 1000-2
IS Sieve Size Per cent by Weight Passing the Sieve

Zone I Zone II Zone III
10mm 100 100 100
4.75mm 90-100 90-100 90-100
2.36mm 60-95 75-100 85-100
1.18mm 30-70 55-90 75-100
600micron 15-34 35-59 60-79
300micron 5-20 8-30 12-40
150micron 0-10 0-10 0-10

1009 STEEL
1009.1 Cast Steel
The use of cast steel shall be limited to bearings and other similar parts. Steel for
castings shall conform to Grade 280-520N of IS: 1030. In case where subsequent
welding is unavoidable in the relevant cast steel components, the letter N at the
end of the grade designation of the steel casting shall be replaced by letter W.
0.3 per cent to 0.5 per cent copper may be added to increase the corrosion
resistance properties.
1009.2 Steel For Prestressing
The prestressing steel shall conform to either of the following:
(a) Plain hard drawn steel wire conforming to IS:1785 (Part I) and IS:1785 (Pan
II).
(b) Cold drawn indented wire conforming to IS:6003
(c) High tensile steel bar conforming to IS:2090
(d) Uncoated stress relieved strands conforming to IS:6006.
1009.3 Reinforcement I Untensioned Steel
For plain and reinforced cement concrete (PCC and RCC) or prestressed
concrete (PSC) works, the reinforcement / untensioned steel as the case may be
shall consist of the following grades of reinforcing bars.
TABLE 1000-3
Bar Type conforming to Characteristic

Grade Elastic
governing IS Strength fy
Designation Modulus GPa
Specification MPa
IS:432 Part I
S 240 240 200
Mild Steel Bar
IS: 1786 High Yield
S 415 Strength 415 200
Deformed Bars (HYSD)
Other grades of bars conforming to IS:432 and IS: 1786 shall not be permitted.
All steel shall be procured from original producers, no re-rolled steel shall be
incorporated in the work.

Only new steel shall be delivered to the site. Every bar shall be inspected before
assembling on the work and defective, brittle or burnt bar shall be discarded.
Cracked ends of bars shall be discarded.
Fusion-bonded epoxy coated reinforcing bars shall meet the requirements of IS:
13620. Additional requirements for the use of such reinforcement bars have been
given below:
(a) Patch up materials shall be procured in sealed containers with certificates

from the agency who has supplied the fusion bonded epoxy bars.
(b) PVC coaled G.I. binding wires of l8G shall only be used in conjunction with
fusion bonded epoxy bars.
(c) Chairs for supporting the reinforcement shall also be of fusion bonded epoxy
coated bars.
(d) The cut ends and damaged portions shall be touched up with repair patch up
material.
(e) The bars shall be cut by saw-cutting rather than flame cutting.
(f) While bending the bars, the pins of work benches shall be provided with PVC
or plastic sleeves.
(g) The coated steel shall not be directly exposed to sun rays or rains and shall
be protected with opaque polyethelene sheets or such other approved materials.
(h) While concreting, the workmen or trolleys shall not directly move on coated
bars but can move on wooden planks placed on the bars.
When specified in the contract, protective coating prescribed by CECRI shall be

provided in conformance to specifications given in Appendix 10001 I. The CECRI
coating process shall be allowed to be implemented at the site of works provided
a representative of the Institute is present throughout the duration of the coating
process who shall certify that the materials and workmanship are in accordance
with prescribed specifications developed by the Institute.
1009.4 Grey Iron Castings
Grey Iron castings to be used for bearings shall have the following minimum
properties:
(i) Minimum ultimate tensile strength 370 MPa
(ii) Modulus of Elasticity 147000 MPa

(iii) Brinell Hardness 230 MPa
(iv) Shear Strength 370 MPa
(v) Compressive Strength 1370 MPa
The testing shall be as specified in IS:210.
1009.5 Steel forgings
Forged steel pins shall comply with" clause 3, 3A or 4 of IS: 1875 and steel
forgings shall comply with clause 3, 3A or 4 of IS:2004. Raw materials of the
forging will be taken as per IS: 1875 with minimum reduction ratio of 1:8:1.
Alternatively, if forging is made from ingot, a minimum reduction ratio between
the "ingot and forging will be 4:1. Forging shall be normalised.
1009.6 Structural Steel
Unless otherwise permitted herein, all structural steel snail before fabrication
comply with the requirements of the following Indian Standards:
IS:226 Structural Steel (Standard Quality)

IS;961 Structural Steel (High Tensile)
IS:2062 Weldable Structural Steel
Weldable Structural Steel (medium & high strength
IS:8500
qualities)
IS:1148 Hot rolled rivet bars (Upto 40mm dial for structural
purpose
IS:1149 High tensile rivet bars for structural purpose
IS:1161 Steel tubes for structural purpose
IS:4923 Hollow steel section for structural purpose
IS:11587 Structural weather resistance steel
Specifications for Rooled steel Beam, Channel and Angle
IS:808
Sections
IS:1239 Mild steel tubes
Dimension for plate, sheet and strip for structural and
IS:1730
general engineering purpose
Dimension for Steel flats for structural and general
IS:1731
engineering purposes
Dimension for round and square steel bars for structural
IS:1732
and general engineering purposes
IS:1852 Rolling and cutting tolerances for hot rolled steel
products

The use of structural steel not covered by the above standards may be permitted
with the specific approval of the authority. Refer to Section 1900f or further details
1009.7 Stainless Steel
Stainless steel shall be austenitic chromium-nickel steel, possessing rust, acid

and heat resistant properties conforming to IS:6603 and IS:6911. Mechanical
properties/grade for such stainless steel shall be as specified by the accepting
authority, but in no case be inferior to mild steel. Generally, stainless steel is
available as per AI51 grades. AISI 304 which is equivalent to grade 04Crl8NiliO
of IS:6911 satisfies the requirements of mechanical properties of structural steel.
Other grades of stainless steel for specific purposes may be provided as per
specific requirements. For application in adverse/ corrosive environment,
stainless steel shall conform to AISI 316L or 02G17 Ni M02 of IS:6911.
1010 WATER
Water used for mixing and curing shall be dean and free from injurious amounts
of oils, acids, alkalis, salts, sugar, organic materials or other substances that may
be deleterious to concrete or steel. Potable water is generally considered
satisfactory for mixing concrete. Mixing and curing with sea water shall not be
permitted. As a guide, the following 'concentrations represent the maximum
permissible values:
(a) To neutralise 200 ml sample of water, using phenolpthalein as an indicator, it

should not require more than 2 ml of 0.1 normal NaOH.
(b) To neutralise 200 ml sample of water, using methyl orange as an indicator, it

should not require more than 10 ml of 0.1 normal HC!.
(c) The permissible limits for solids shall be as follows when tested in accordance
with IS:3025 :
Permissible limits (max)
Organic 200 mg/lit
Inorganic 3000 mg/lit
Sulphates (S04) 500 mg/lit
Chlorides (CI) 500 mg/lit
Suspended matter 2000 mg/lit

* In case of structures of lengths 30m and below, the permissible limit of chlorides
may be increased upto 1000 mg/lit.
All samples of water (including potable water) shall be tested and suitable
measures taken where necessary to ensure conformity of the water to the
requirements stated herein.
(d) The pH value shall not be less than 6.
1011 TIMBER
The timber used for structural purposes shall conform to IS:883.
1012 CONCRETE ADMIXTURES
1012.1 General
Admixtures are materials added to the concrete before or during mixing with a
view to modify one or more of the properties of concrete in the plastic or
hardened state.
Concrete admixtures are proprietary items of manufacture and shall be obtained

only from established manufacturers with proven track record, quality assurance
and full fledged laboratory facilities for the manufacture and testing of concrete.
The contractor shall provide the following information concerning each admixture
after obtaining the same from the manufacturer:
(a) Normal dosage and detrimental effects, if any, of under dosage and over
dosage.
(b) The chemical names of the main ingredients in the admixtures.
(e) The chloride content, if any, expressed as a percentage by the weight of the
admixture.
(d) Values of dry material content, ash content and relative density of the
admixture which can be used for Uniformity Tests.
(e) Whether or not the admixture leads to the entertainment of air when used as
per the manufacturer's recommended dosage, and if so to what extent
(f) Where two or more admixtures are proposed to be used in anyone mix,
confirmation as to their compatibility.
(g) There would be no increase in risk of corrosion of the reinforcement or other

1012.2 Physical and Chemical Requirements
Admixtures shall conform to the requirements of IS:9103. In addition, the

following conditions shall be satisfied:
(a) "Plasticisers" and "Super-Plasticisers" shall meet the requirements indicated

for "Water reducing Admixture".
(b) Except where resistance to freezing and thawing and to disruptive action of
de-icing salts is necessary, the air content of freshly mixed concrete in
accordance with the pressure method given in IS: 1199 shall not be more than 2
per cent higher than that of the corresponding control mix and in any case not
more than 3 per cent of the test mix.
(c) The chloride content of the admixture shall not exceed 0.2 per cent when
tested in accordance with IS:6925. In addition, the maximum permissible limit of
chloride content of all the constituents as indicated in Section 1700 shall also be
observed.
(d) Uniformity tests on the admixtures are essential to compare qualitatively the
composition of different samples taken from batch to batch or from the same
batch at different times.
The tests that shall be performed along with permissible variations in the same
are indicated below:
Dry Material Content: to be within 3 per cent and 5 per cent of liquid and solid
admixtures respectively of the value stated by the manufacturer.
Ash content : to be within 1 per cent of the value stated by the manufacturer.
Relative Density (for liquid admixtures): to be within 2 per cent of the value stated
by the manufacturer.
(e) All tests relating to the concretes admixtures shall be conducted periodically
at an independent laboratory and compared with the data given by the
manufacturer.
1013 REINFORCED CONCRETE PIPES
Reinforced concrete pipes for highway structures shall. be of NP4 type

conforming to the requirements of IS:458.

1014 STORAGE OF MATERIALS
1014.1 General
All materials may be stored at proper places so as to prevent their deterioration

or intrusion by foreign matter and to ensure their satisfactory quality and fitness
for the work. The storage space must also permit easy inspection, removal and
restorage of the materials. All such materials even though stored in approved
godowns/places, must be subjected to acceptance test prior to their immediate
use.
1014.2 Brick
tiers as they are unloaded, to minimise breakage and defacement. The supply of
bricks shall be available at site at any time. Bricks selected for use in different
situations shall be stacked separately.
1014.3 Aggregates
Aggregate stockpiles may be made on ground that is denuded of vegetation, is

hard and well drained. If necessary, the ground shall be covered with 50 mm
plank.
Coarse aggregates, unless otherwise agreed by the Engineer in writing, shall be

delivered to the site in separate sizes (2 sizes when nominal size is 25 mm or
less and 3 sizes when the nominal size is 32 mm or more). Aggregates placed
directly on the ground shall not be removed from the stockpile within 30 cm of the
ground until the final cleaning up of the work, and then only the clean aggregate
will be permitted to be used.
In the case of fine aggregates, these shall be deposited at the mixing site not less
than 8 hours before use and shall have been tested and approved by the
Engineer.
1014.4 Cement
Cement shall be transported, handled and stored on the site in such a manner as
to avoid deterioration or contamination. Cement shall be stored above ground
level in perfectly dry and water-tight sheds and shall be stacked not more than
eight bags high. Wherever bulk storage containers are used their capacity should
be sufficient to cater to the requirement at site and should be cleaned at least
once every 3 to 4 months.

Each consignment shall be stored separately so that it may be readily identified

and inspected and cement shall be used in the sequence in which it is delivered
at site. Any consignment or part of a consignment of cement which had
deteriorated in any way, during storage, shall not be used in the works and shall
be removed from the site by the Contractor without charge to the Employer.
The Contractor shall prepare and maintain proper records on site in respect of
delivery, handling, storage and use of cement and these records shall be
available for inspection by the Engineer at all times.
The Contractor shall make a monthly return to the Engineer on the date
corresponding to the interim certificate date, showing the quantities of cement
received and issued during the month and in stock at the end of the month.
1014.5 Reinforcement /Untensioned Steel
The reinforcement bars, when delivered on the job, shall be stored above the
surface of the ground upon platforms, skids, or other supports, and shall be
protected from mechanical injury and from deterioration by exposure.
1014.6 Prestressing Materials
All prestressing steel, sheathing, anchorages and sleeves or coupling must be

protected during transportation, handling and storage. The prestressing steel,
sheathing and other accessories must be stored under cover from rain or damp
ground and protected from the ambient atmosphere if it is likely to be aggressive.
Storage at site must be kept to the absolute minimum.
(a) Tendon: Wire, strand and bar from which tendons are to be fabricated shall be
stored about 300mm above the ground in a suitably covered and dosed space so
as to avoid direct climatic influences and to protect them from splashes from any
other materials and from the cutting operation of an oxy-acetylene torch or arc
welding process in the vicinity. Under no circumstances, tendon material shall be
subjected to' any welding operation or on site heat treatment or metallic coating
such as galvanising. Storage facilities and the procedures for transporting
material into or out of store, shall be such that the material does not become
kinked or notched. Wire or strand shall be stored in large diameter coils which
enable the tendons to be laid out straight As a guide, for wires above 5mm dia,
coils of about 2m dia without breaks or joints shall be obtained from manufacturer
and stored. Protective wrapping for tendons shall be chemically neutral. All
prestressing steel must be provided with temporary protection during storage.

(b) Anchorage
Components : The handling and storing procedures shall maintain the

anchorage components in a condition in which they can subsequently perform
their function to an adequate degree.
Components shall be handled and stored so that mechanical damage and

detrimental corrosion are prevented. The corrosion of the gripping and securing
system shall be prevented. The use of correctly formulated oils and greases or of
other corrosion preventing material is recommended where prolonged storage is
required. Such protective material shall be guaranteed by the producer to be non-
aggressive and non-degrading.
Prestressing steel shall be stored in a closed store having single door with double
locking arrangements and no windows. Also the air inside the store shall be kept
dryas far as possible by using various means to the satisfaction of the Engineer.
Also instrument measuring the air humidity shall be installed inside the store. This
is with a view to eliminating the possibility of initial rusting of prestressing steel
during storage. The prestressing steel shall be coated with water solvable-
grease. The prestressing steel should be absolutely clean and without any signs
of rust.
All prestressing steel shall be stored at least 30 cm above ground level and it
shall be invariably wrapped by protective cover of tar paper or polythene or any
other approved material.
The Contractor should see that prestressing steel shall be used within 3 months
of its manufacture. He should chalk out his programme in this respect precisely,
so as to avoid initial corrosion before placing in position.
1014.7 Water
Water shall be stored in containers/tanks covered at top and cleaned at regular

intervals in order to prevent intrusion by foreign matter or growth of organic
matter. Water from shallow, muddy or marshy surface shall not be permitted. The
intake pipe shall be enclosed to exclude silt, mud, grass and other solid materials
and there shall be a minimum depth of 0.60 m of water below the intake at all
times.
1015 TESTS AND STANDARD OF ACCEPTANCE
All materials, even though stored in an approved manner shall be subjected to an

acceptance test prior to their immediate use.

Independent testing of cement for every consignment shall be done by the

Contractor at site in the laboratory approved by the Engineer before use. Any
cement with lower quality than those shown in manufacturer's certificate shall be
debarred from use. In case of imported cement, the same series of tests shall be
carried out before acceptance.
1015.1 Testing and Approval of Material
The Contractor shall furnish test certificates from the manufacturer/ supplier of
materials along with each batch of material(s) delivered to site.
The Contractor shall set up a field laboratory with necessary equipment for
testing of all materials, finished products used in the construction as per
requirements of conditions of contract and the relevant specifications. The testing
of all the materials shall be carried out by the Engineer or his representative for
which the Contractor shall make all the necessary arrangements and bear the
entire cost.
Tests which cannot be carried out in the field laboratory have to be got done at
the Contractor's cost at any recognised laboratory / testing establishments
approved by the Engineer.
1015.2 Sampling of Materials
Samples provided to the Engineer or his representative for their retention are to
be in labelled boxes suitable for storage.
Samples required for approval and testing must be supplied well in advance by at
least 48 hours or minimum period required for carrying out relevant tests to allow
for testing and approval. Delay to works arising from the late submission of
samples will not be acceptable as a reason for delay in the completion of the
works.
If materials are brought from abroad, the cost of sampling/testing whether in India
or abroad shall be borne by the Contractor.
1015.3 Rejection of Materials not Conforming to the Specifications
Any stack or batch of material(s) of which sample(s) does not conform to the
prescribed tests and quality shall be rejected by the Engineer or his
representative and such materials shall be removed from site by the Contractor at
his own cost. Such rejected materials shall not be made acceptable by any
modifications.

1015.4 Testing and Approval of Plant and Equipment
All plants and equipment used for preparing, testing and production of materials
for incorporation into the permanent works shall be in accordance with
manufacturer's specifications and shall be got approved by the Engineer before
use.

1100 PILE FOUNDATIONS

1101 DESCRIPTION
1101.1 This work shall consist of construction of all types of piles for structures in
accordance with the details shown on the drawings and conforming to the
requirements of these specifications.
1101.2 The construction of pile foundations requires a careful choice of the piling system
depending upon sub-soil conditions and loading characteristics and type of
structure. The permissible limits of total and differential settlements, unsupported
length of pile under scour, impact / entanglement of floating bodies and any other
special requirements of project are also equally important criteria for selection of
the piling system. The method of installing the piles, including details of the
equipment shall be submitted by the Contractor and got approved from the
Engineer.
1101.3 The work shall be done as per IS:2911 except as modified herein.
1102 SUB-SURFACE INVESTIGATION
1102.1 The complete sub-surface investigation of strata in which pile foundations are
proposed shall be carried out in advance and by in-situ pile tests. For details of
geotechnical sub-surface explorations reference may be made to Section 2400.
At least one bore-hole for every foundation of the bridge shall be executed.
Borings should be carried upto sufficient depths so as to ascertain the nature of
strata around the pile shaft and below the pile tip. However, depth of boring shall
not be less than:
i) 1.5 times estimated length of pile in soil but not less than 15m beyond the
probable length of pile
ii) 15 times diameter of pile in weak/jointed rock but minimum 15m in such rock
iii) 4 times diameter of pile in sound, hard rock but minimum 3m in such rock
1102.2 The sub-surface investigation shall define adequately stratification of sub-strata

including the nature and type of strata, its variation and extent and specific
properties of the same. The investigation shall be adequate for the purpose of
selection of appropriate piling system and for estimating design capacities for
different diameters and length of piles.
1102.3 Pressure meter tests may be used in the case of rock, gravel or soil for direct
evaluation of strength and compressibility characteristics. Though these tests are

of specialized nature they are most appropriate for difficult/uncertain sub-strata

especially for important projects.
1102.4 For piles socketed into rocks, it is necessary to determine the uniaxial
compressive strength of the rock and its quality.
The investigation shall also include location of ground water table and other
parameters including results of chemical tests showing sulphate and chloride
content and any other deleterious chemical content in soil and/or ground water,
likely to affect durability.
1103 TYPE OF PILES
The piles may be of reinforced concrete, prestressed concrete, steel or timber.

The piles may be of solid or hollow sections or steel cased piles filled with
concrete. Concrete piles may be driven cast-in-situ or precast or bored cast-in-
situ or precast piles driven into preformed bores. The shape of piles may be
circular, square, hexagonal, octagonal, "H" or "I" Section.
1104 MATERIALS
1104.1 The basic materials shall conform to the specifications for materials given in
Section 1000. The specifications for steel reinforcement, structural concrete,
prestressed concrete and structural steel to be used in pile foundations shall be
as given in the relevant sections.
1104.2 Concrete in Piles
Grade of concrete to be used in cast-in-situ piles shall not be less than M 20 and
the cement content shall not be less than 400 kg per cubic meter of concrete.
Grades of concrete for precast reinforced and prestressed concrete piles shall
not be less than M 25 and M 35 respectively. Maximum water cement ratio shall
be 0.5 for cast-in-situ piles and 0.45 for precast piles. (Clause 709.1.9 of IRC:78:
2000 was amended as IRC notification No: 54 dated 28.05.2009)
For both precast and cast-in-situ-piles, the values regarding grade of concrete,
water cement ratio, slump shall be as follows:
TABLE 1100-1 PROPERTIES OF CONCRETE
Concrete Cast-in-situ
Precast Concrete
by Tremie

Grade of Concrete M 35 M 35
Min. cement concretes 400 kg/m3 400 kg/m3
Max. WC ratio 0.4 0.4
Slump (mm) 150-200 50-75
The minimum slump of concrete for driven cast-in-situ piles shall be 100 mm to
150 mm and that of bored cast-in-situ piles 150 mm to 200 mm. The slump
should not exceed 200 mm in any case.
Concrete mix should have homogeneous mixture with required workability for the
system of piling adopted. Suitable and approved admixtures may be used in
concrete mix where necessary.
Where piles are exposed to action of harmful chemicals or severe conditions of

exposure due to presence of sulphate, chloride etc, it may be preferable to opt for
higher grades of concrete restricting water cement ratio to 0.45. Special types of
cement, such as sulphate resistant cement may be used where considered
appropriate.
The minimum diameter of piles shall be 1.0m for river/marine bridges. For bridges
beyond the water zones and for bridges on land the diameter may be reduced
upto 750 mm (Clause 709.1.7 of IRC:78: 2000 was amended as IRC notification
No: 54 dated 28.05.2009)
1105 TEST PILES
1105.1 Test piles which are shown on the drawings or specified in the contract or
installed by the Contractor on his own to determine the lengths of piles to be
furnished shall conform to the requirements for piling as indicated in these
specifications, if they are to be incorporated in the completed structure.
Test piles that are to become a part of the completed structure shall be installed
with the same type of equipment that is proposed to be used for piling in the
actual structure.
Test piles which are not to be incorporated in the completed structure shall be
removed to at least 600 mm below the proposed soffit level of pile cap and the
remaining hole shall be backfilled with earth or other suitable material.

The piles shall be load tested in accordance with provisions laid down in this
section.
1106 PRECAST CONCRETE PILES
1106.1 General
Precast concrete piles shall be of the size and shape as shown in the approved
drawings. If a square section is employed, the corners shall be chamfered at
least 25 mm unless otherwise specified on the drawings. The length of pile shall
not normally exceed 25 metres. However, where special equipments for handling
and installation are available to the satisfaction of the Engineer, longer length
could be permitted.
Piles shall be cast with a driving point and for hard driving, shall be shod with a
metal shoe approved by the Engineer.
1106.2 Stacking, Storing and Handling
Care shall be taken that at all stages of transporting, lifting and handling, piles are
not damaged or cracked. During transport and stacking of piles, they shall be
supported at the same points as those provided for lifting purposes. If the piles
are put down temporarily during handling, they shall be placed on trestles or
blocks located at the same points.
Plies shall be stored at least 300 mm above firm level ground which is not liable
to unequal subsidence or settlement under the weight of the stack of piles. They
shall be placed on Umber supports which are level and spaced so as to avoid
bending. The supports shall be vertically one above the other. Spaces shall be
left round the piles to enable them to be lifted without difficulty. The order of
stacking shall be such that the older piles can be withdrawn without disturbing
newer piles. Separate stacks shall be provided for different lengths of piles.
Where piles are stacked in layers, the number of layers shall not exceed three.
Whenever curing is needed during storage, arrangements shall be made to

enable the piles to be watered. For detailed precautions with regard to curing
operations specifications for structural concrete given in Section 1700 shall apply.
Before the operation of handling and driving the piles, the minimum periods
counted from the time of casting shall be allowed for as indicated in Table 1100-
1. Prestressed piles shall not be lifted or handled until fully stressed.
TABLE 1100-2 TIME FOR CURING PRECAST PILES

Type of cement used In

Minimum periods from time of casting
casting, the pile
Strike
End of wet Lift from
side- Drive
curing casting bed
shutters (days)
(days) (days)
(hours)
Ordinary Portland 22 7 10 28
Rapid hardening Portland 12 7 7 10
1106.3 Lengthening of Piles
Where a pile is to have another length cast on it during driving, the longitudinal
reinforcement shall preferably be joined by full penetration butt welding. The
concrete at the top of the original pile shall be cut down to expose not less than
200 mm of the bars to avoid spalling of the concrete by heat. The added bars
have to be held accurately and rigidly in position during welding. Where facilities
on site are insufficient to make proper butt welding practicable, the joint may be
made by lapping. The reinforcement at the head of pile will need to be exposed
for full anchorage length or 600 mm whichever is greater and the new bars over-
lapped for this distance. Unless otherwise specified, the, extension of the pile
shall be formed to the same cross-sectional profile and with concrete of at least
the same strength as that specified for the original pile. The stirrup spacing shall
in no case be greater than 150 mm. Not more than one extension shall be
permitted. In case more than one extension is permitted by the Engineer, only
approved mechanical couplers shall be used.
Driving shall not be resumed until:
(i) The strength of the concrete in the extension is at least equal to the specified
characteristic strength of concrete in pile, and
(ii) The approval of the Engineer has been obtained.
1106.4 Removal of Surplus length
Any length of pile surplus to that required for incorporation in the structure shall
be cut off neatly and removed. During the process of cutting off, it shall be
ensured that projecting reinforcement to be anchored into the pile cap and the
prestressing strands/wires are not damaged. When stripping prestressed
concrete piles, shock release of tendons shall be avoided. Reference may also
be made to clause 7.7.1. of IS:2911 (Part I Section 3) in this connection.

1106.5 Risen Piles
Level reading should be taken on each pile after driving and again after all the
piles are driven. Piles which are found to have risen due to ground heave or as a
result of driving adjacent piles, shall be re-driven to the original depth or
resistance unless re-driving tests on adjacent piles have shown this to be
unnecessary.
1106.6 Manufacture
The pile should be cast in one continuous operation from end to end of each pile.
Manufacture of precast concrete piles shall conform to the guidelines contained
in clause Nos. 7.1, 7.2 and 7.3 of IS:2911 (Part I, Section 3).
Pile shall be provided with suitable shoe for protecting the point of the pile during
driving in hard ground.
Piles shall not be moved from casting bed until the concrete has hardened
sufficiently.
Piles shall not be driven in less than 28 days after casting or unless their strength
at the time of driving is at least that specified for 28 days.
1106.7 Prestressed Concrete Piles
Additional specifications for precast prestressed concrete piles shall conform to

those contained in clause 8 of IS:2911 (Part 1 Section 3).
1107 CAST-IN-SITU CONCRETE PILES
Cast-in-situ concrete piles may be either installed by making a bore into the
ground by removal of material or by driving a metal casing with a shoe at the tip
and displacing the material laterally. The two types of piles are termed as "bored
piles" and "driven piles" respectively. Cast-in-situ concrete piles may be cast in
metal shells which may remain permanently in place. However, other types of
cast-in-situ concrete piles, plain or reinforced, cased or uncased, may be used if
in the opinion of the Engineer the soil conditions permit their use and if their
design and the methods of placing are satisfactory.
The metal casing shall be of sufficient thickness and strength to hold its. original
form and show no harmful distortion after it and adjacent casings have been
driven and the driving core, if any, has been withdrawn. Cast-in-situ concrete
driven piles shall be installed using a properly designed detachable shoe at the

bottom of the casing. Certain specific requirements of cast-in-situ driven piles

shall be as per Clauses 1110 and 1111.
Any liner or bore-hole which is improperly located or shows partial collapse that
would affect the load carrying capacity of the pile, shall be rejected or repaired as
directed by the Engineer at the cost of the Contractor. The minimum thickness of
liner shall be 6mm. (Clause 709.1.4 of IRC:78: 2000 was amended as IRC
notification No: 54 dated 28.05.2009)Wherever practicable, concrete should be
placed in a clean dry hole. Where concrete is placed in dry and there is casing
present, the top 3 m of the pile shall be compacted using internal vibrators. The
concrete should invariably be poured through a tremie with a funnel so that the
flow is directed and concrete can be deposited in the hole without segregation.
Where the casing is withdrawn from cohesive soils for the formation of cast-in-
situ pile, the concreting should be done with necessary precautions to minimize
the softening of the soil by excess water. Where mud flow conditions exist, the
casing of cast-In-situ piles shall not be allowed to be withdrawn.
Care shall be taken during concreting to prevent as far as possible the

segregation of the ingredients. The displacement or distortion of reinforcement
during concreting and also while extracting the tube shall be avoided.
If the concrete is placed inside precast concrete 'tubes or consists of precast

sections, these shall be free from cracks or other damage before being installed.
The concrete shall be properly graded, shall be self-compacting and shall not get
mixed with soil, excess water, or other extraneous matter.
Special care shall be taken in silty clays and other soils with the tendency to
squeeze into the newly deposited concrete and cause necking. Sufficient head of
green concrete shall be maintained to prevent inflow of soil or water into the
concrete.
The placing of concrete shall be a continuous process from the toe level to the
top of the pile. To prevent segregation, a tube or tremie pipe as appropriate shall
be used to place concrete in all piles.
To ensure compaction by hydraulic static heads, rate of placing concrete in the

pile shaft shall not be less than 6 m (length of pile) per hour.
Bored cast-in-situ piles in soils which are stable, may often be installed with only
a small casing length at the top. A minimum of 2.0m length of top of bore shall
invariably be provided with casing to ensure against loose soil falling into the

bore. In cases in which the side soil can fall into the hole, it is necessary to
stabilise the side of the bore hole with drilling mud, or a suitable steel casing. The
casing may be left in position permanently specially in cases where the
aggressive action of the ground water is to be avoided, or in the cases of piles
built in water or in cases where significant length of piles could be exposed due to
scour.
For bored cast-in-situ piles, casing/liner shall be driven open ended with a pile
driving hammer capable of achieving penetration of the liner to the length shown
on the drawing or as approved by the Engineer. Materials inside the casing shall
be removed progressively by air lift, grab or percussion equipment or other
approved means.
Where bored cast-in-situ piles are used in soils liable to flow, the bottom of the
casing shall be kept enough in advance of the boring tool to prevent the entry of
soil into the casing, thus preventing the formation of cavities and settlements in
the adjoining ground. The water level in the casing should generally be
maintained at the natural ground water level for the same reasons. The joints of
the casing shall be made as tight as possible to minimise inflow of water or
leakage of slurry during concreting.
Boring shall be carried out using rotary or percussion type equipment. Unless
otherwise approved by the Engineer, the diameter of the bore-holes shall be not
more than the inside diameter of the liner. Prior to the lowering of the
reinforcement cage )nto the pile shaft, the shaft shall be cleaned of all loose
materials. Cover to reinforcing steel shall be maintained by suitable spacers.
The diameter of the finished pile shall not be less than that specified and a
continuous record shall be kept by the Engineer as to the volume of concrete
placed in relation to the pile length cast.
Before concreting under water, the bottom of the hole shall be cleaned of drilling
mud and all soft or loose material very carefully. In case a hole is bored with use
of drilling mud, concreting should not be taken up when the specific gravity of
bottom slurry is more than 1.2. The drilling mud should be maintained at 1.5m
above the ground water level.
Concreting under water for cast-in-situ concrete piles may be done either with the
use of tremie method or by the use of an approved method specially designed to
permit under water placement of concrete.

General requirements and precautions for concreting under water are as follows:
(a) The concreting of a pile must be completed in one continuous operation. Also,
for bored holes, the finishing of the bore, cleaning of the bore, lowering of
reinforcement cage and concreting of pile for full height must be accomplished in
one continuous operation without any stoppage.
(b) The concrete should be coherent, rich in cement with high slump and
restricted water cement ratio.
(c) The tremie pipe will have to be large enough with due regard to the size of
aggregate. For 20 mm aggregate the tremie pipe should be of diameter not less
than 150 mm and for larger aggregate, larger diameter tremie pipes may be
necessary.
(d) The first charge of concrete should be placed with a sliding plug pushed down
the tube ahead of it to prevent mixing of water and concrete.
(e) The tremie pipe should always penetrate well into the concrete with an
adequate margin of safety against accidental withdrawal if the pipe is surged to
discharge the concrete.
(f) The pile should be concreted wholly by tremie and the method of deposition
should not be changed part way up the pile to prevent the laitance from being
entrapped within the pile.
(g) All tremie tubes should be scrupulously cleaned after use.
1108 STEEL PILES
Steel piles shall be "H" or "I" sections as shown on the drawings and shall be of
structural steel conforming to the specifications given in Section 1000.
Steel piles shall be protected by suitable anti-corrosive painting as specified on

the drawing. Piles shall be stored above the ground using protective packing to
minimise damage to surface coating. Each pile shall be supplied preferably in
one piece without splices.
At the option of the Contractor, steel piling consisting of structural steel plates
welded together may be substituted for the rolled sections specified, provided
that the depth, width and average thicknesses are to at least equal to those of the
rolled sections, the steel plates conform to specification given in Section 1000,
the flanges are welded to the web with continuous fillet welds on either side of the
web, and twelding conforms to Clause 1904.8 of these specifications.

The length of the steel pile may be built up in sections either before or during
driving operations. The sections shall be of identical cross-section. Pile splices
shall be made with full penetration butt welds over the whole cross-section. Pile
splices shall develop at least the yield strength of pile.
The connections shall be made by butt-welding the entire cross section in

accordance with the provisions in Clause 1904.8 of these specifications. Care
shall be taken to properly align the sections connected so that the axis of the pile
will be straight. The number of welded connections in the length of the pile shall
be as few as possible.
1109 TIMBER PILES
The Engineer shall stamp each pile on the butt with a stamp which shall make an
impression that is readily legible. Treated timber piles will be inspected by the
Engineer after treatment.
Untreated timber may be used as test piles.
Untreated timber piles and treated timber piles shall be of approved quality.
Treated timber piles shall be driven within 6 months after treatment.
Timber piles shall be furnished with tip protection and shall be protected by the
use of steel straps as hereinafter specified. Tip protection shall be suitable for
use on timber piling of the size to be driven. Details of tip protection shall be
furnished to the Engineer for review and approval before driving piles. Not less
than 2 separate steel straps shall be placed within 600 mm of the butt of each
pile after the pile is square cut. Not less than 2 separate steel straps shall be
placed within 300 mm of the tip of each pile.
Additional intermediate steel straps shall be placed at not more than 3 metres
centre measured along the length of the pile.
Timber piles which are to be capped shall be separately cut off so that true
bearing is obtained on every pile. Piles inaccurately cut off shall be replaced.
Splicing of timber piles shall not be permitted except by written permission of the
Engineer.
1110 DRIVING EQUIPMENT
Piles or their casings may be driven with any type of drop hammer, diesel
hammer or single-acting steam or compressed air hammer, provided they
penetrate to the prescribed depth or attain the designed resistance without being

damaged. The weight or power of the hammer should be sufficient to ensure a

penetration of at least 5 mm per blow, unless rock has been reached. It is always
preferable to employ the heaviest hammer practicable and to limit the stroke, so
as not to damage the pile. The minimum weight of the hammer shall be 2.5t. In
the case of precast concrete piles the mass of the hammer shall be not less than
30 times the mass of 300 mm length of pile.
Steam or air hammers shall be furnished along with boiler or air compressor of
capacity at least equal to that specified by the manufacturer of the hammers. The
boiler or air compressor shall be equipped with an accurate pressure gauge at all
times. The valve mechanism and other parts of steam, air or diesel hammers
shall be maintained in first class condition so that the length of stroke and number
of blows per minute for which the hammer is designed, will be obtained.
Inefficient steam, air or diesel hammers shall be removed from the work.
1111 DRIVING
1111.1 General Procedure
Details of the equipment and the method proposed for driving the piles shall be
submitted with the tender for scrutiny and approval of the Engineer.
Piles shall be installed from firm ground or from temporary supports or from fixed
platform. The arrangement shall provide sufficient rigidity to ensure accuracy of
pile driving under all conditions of tide, stream flow or hammer drop.
During driving the top of pile shall be protected by a suitable helmet of substantial
steel construction. The helmet shall provide uniform bearing across the top of the
pile and shall hold the pile centrally under the hammer. No pile shall be driven
unless inspected and approved by the Engineer.
Piles shall be driven from a fixed frame of sufficient rigidity to ensure accuracy of
driving within specified tolerances. Forces producing undue bending or torsional
stresses in piles shall not be applied during driving. The force of the hammer
shall be directed centrally and axially during driving.
The stroke of a single acting or drop hammer shall be limited to 1.2 m unless
otherwise permitted by the Engineer. A shorter stroke may be necessary when
there is danger of damaging the pile.
Piles shall not be bent or sprung into position but shall be effectively guided and
held on-line during the initial stages of driving. Attempts to correct any tendency
for the pile to run off-line by the application of significant horizontal restraint will

hot be permitted. Shortly after the commencement of driving and at regular

intervals throughout the driving operation, checks shall be made to ensure that
the pile frame does not exert any undue lateral force on the pile due to restraint
within the helmet
If the indications are that a pile will finish outside the specified tolerances, driving
operations on that pile will cease. The pile shall be withdrawn, the hole filled and
the pile re-driven at no extra cost.
To avoid the possibility of premature "set-up" pile driving shall be continuous in

the later stages, without any deliberate stops. (Delays of an hour or less may lead
to significant "set-up" in piles i.e. resistance to further driving increases after
driving is stopped).
If any pile is damaged in any way during driving, it shall be repaired or replaced
as directed by the Engineer, at no extra cost. If during driving, the head of a pile
is damaged to the extent that further driving is not possible, the head shall be cut
off and driving continued. The cost of cutting off shall be borne by the Contractor
and where, as a result of such cutting off the head, the pile is too short, the
Contractor, shall, at his own cost, supply and splice on sufficient length of pile to
restore the pile to its correct length.
Piles should be driven to the minimum acceptable penetration shown on the

drawings. This may require preboring and/or jetting as indicated in these
specifications with the full approval of the Engineer.
Piles shall be driven to nominal refusal or the required ultimate dynamic capacity
nominated on the drawings or until the top of the pile is at the level required and
specified on the drawing whichever gives the lowest toe elevation. The
Engineer's decision in these matters shall be final. Nominal refusal shall be taken
as equivalent to 25 mm total penetration for the final 20 blows using a hammer of
driving energy as specified and shall be used as the criterion for acceptance for
piles founded on rock. Severe driving which results in an average set per blow
less than 0.5 mm will not be permitted.
Where hard drilling is encountered because of dense strata or obstructions

located above the predetermined pile tip level, nominal refusal shall not be
considered to have been achieved unless the Engineer is satisfied that the total
number of blows, as the average driving resistance specified for nominal refusal,
indicates that further driving will not advance the pile through dense strata or
obstructions.

The pile shall be driven as accurately as possible to the vertical or to specified

batter. Straining the pile into position can damage it and the driving equipment
should be adjusted as much as possible to follow the position of the pile. Any
deviation from the proper alignment shall be noted and promptly reported to the
Engineer. If the deviation is to such an extent that the resulting eccentricity
cannot be taken care of by strengthening the pile cap or pile ties, such a pile
shall, at the discretion of the Engineer, be replaced or supplemented by an
additional pile. Unless otherwise specified, the permissible positional deviation for
piles shall be limited to those indicated in Clause 1116.
Care shall be taken not to damage the pile by over-driving. Any sudden change in
the rate of penetration which cannot be ascribed to the nature of the ground shall
be noted and its cause ascertained, if possible, before driving is continued.
When employing a tube which is subsequently withdrawn for the formation of

cast-in-situ pile, consideration shall be given to the possibility of doing harm to a
pile recently formed by driving the tube nearby before the concrete has
sufficiently set. The danger of doing harm is greater in compact soils than loose
soils. No pile shall be bored or driven within 3 m of a newly cast pile until at least
24 hours after completion of its installation.
Driving piles in loose sand tends to compact the sand which in turn increases the
skin friction. Therefore, driving a number of friction piles in a group shall proceed
outward from the centre as otherwise it will be difficult to drive the inner piles to
the same depth as the others.
In the case of stiff clay also, the driving for a group of piles shall proceed outward
from the centre. However, in case of very soft soil, the driving may proceed from
outside to inside, so that the soil is restrained from flowing out during driving
operations.
If there is a major variation between the depth at which adjacent foundation piles
in a group meet refusal, a boring shall be made nearby to ascertain the cause of
this difference. If the boring shows that the soil contains pockets of highly
compressive material below the level of the shorter pile, it will be necessary to
enforce penetration of all the piles to a level below the bottom of the zone which
shows such pockets.

1111.2 Preboring and Jetting
Driving of the piles may be assisted by pre boring holes or by the use of jets or
both subject to the approval of the Engineer. These may be used essentially to
achieve the minimum penetration shown on the drawings where such penetration
is not reached under normal conditions of driving indicated in Clause 1111.1.
The diameter of the hole shall not be greater than the diagonal dimension of the
pile less 100 mm.
The maximum depth of the preboring shall be such that the specified set (or less)
is obtained when the toe of the pile is at founding level.
Preboring shall be as approved by the Engineer and shall not extend below one
metre above the founding level and the pile shall be driven to at least one metre
below the prebored hole. To ensure that the pile is properly supported laterally in
the hole, any space remaining around the pile at the ground level after driving is
finished shall be backfilled with approved granular material.
When water jetting is used, at least two jets shall be attached to the pile
symmetrically when this type of technique is used. The volume and pressure of
water at the outlet nozzles shall be sufficient to freely erode material adjacent to
the toe of the pile. The maximum depth of jetting shalf be such that the specified
set (or less) is obtained when the toe of the pile is at founding level. Jetting shall
cease as directed by the Engineer and shall not proceed below one metre above
the founding level and the pile shall be driven at least one metre below the pre-
bored hole.
To avoid very hard driving and vibration in materials, such as sand, jetting of piles
by means of water may be carried out only by express permission of the
Engineer and in such a manner as not to impair the bearing capacity of piles
already in place, the stability of the soil or the safety of any adjoining buildings.
Details of the arrangement for jetting shall be gol approved from the Engineer in
advance.
If, for jetting, large quantities of water are used, it may be necessary to make
provision for collection of water when it comes to the ground surface, so that the
stability of the piling plant is not endangered by the softening of the ground.
Jetting shall be stopped before completing the driving which shall always be
finished by ordinary methods. Jetting shall be stopped if there is any tendency for

the pile tips to be drawn towards the pile already driven owing to the disturbance
to the ground.
1112 RAKER (INCLINED) PILES
The maximum rake to be permitted in piles shall not exceed the following:
i) 1 in8 for large diameter cast-In-situ piles viz 0.75 m diameter and above
ii) 1 in 5 for smaller diameter cast-in-situ piles
iii) 1 in4 for precast driven piles
1113 PILE TESTS
1113.1 General
The bearing capacity of a single pile may be determined from test loading a pile.
The load test on a concrete pile may not be carried out earlier than 28 days from
the time of casting of the pile.
There shall be two categories of tests on piles, namely, initial tests and routine
tests. Initial tests should be carried out on test piles which are not to be
incorporated in the work. Routine tests shall be carried out as a check on working
piles. The number of initial and routine tests on piies shall be as determined by
the Engineer depending upon the number of foundations, span length, type of
superstructure and uncertainties of founding strata. In any case, the initial load
tests shall not be less than 2 in number, while the routine load tests shall not be
less than 2 per cent of the total number of piles in the structure nor less than 2 in
number.
The above stipulations hold good for both vertical as well as lateral load tests on
pile foundations.
However, both initial and routine tests may be suitably increased for important
structures or cases with large variation in the subsurface strata.
The methodology of carrying out load tests and of arriving at safe load on piles
shall conform to IS:2911 (Part IV).
In case of any doubt of workmanship or load carrying capacity of working piles

not subjected to routine tests, or when ordered. by the Engineer, or when
provided in the contract, load tests on working piles may be supplemented by
non-destructive testing. Such tests may include "Integrity Testing" of concrete in
the installed pile and utilisation of "Pile Driving Analyser" which gives an
indication of pile capacity in end bearing and side friction.

1114 PILE CAP
Pile Caps shall be of reinforced concrete. A minimum offset of 150 mm shall be

provided beyond the outer faces of the outer most piles in the group. If the pile
cap is in contact with earth at the bottom, a levelling course of minimum 100 mm
thickness of M 15 nominal mix concrete shall be provided.
The attachment of the pile head to the cap shall be adequate for the transmission
of loads and forces. A portion of pile top may be stripped of concrete and the
reinforcement anchored into the cap. Manual chipping may be permitted after
three days of pile casting, while pneumatic tools for chipping shall not be used
before seven days after pile casting. The top of pile after stripping shall project at
least 150 mm into the pile cap. A layer of surface reinforcement may be provided
with a cover of 25 mm to retain the integrity of concrete below the main cap
reinforcement which is to be laid 25 mm above the pile top.
Concreting of the pile cap shall be carried out in dry conditions. The bottom of the
pile cap shall be laid preferably as low as possible taking account of the water
level prevalent at the time of casting.
The top of concrete in a pile shall be brought above cut-off level to permit
removal of all laitance and weak concrete before pile cap is laid. This will ensure
good concrete at the cut-off level.
The minimum thickness of pile cap should be atleast 1.5 times diameter of pile .
Such a cap can be considered as rigid. Casting of pile cap should be at level
higher than water level unless functionally it is required to be below water level at
which time sufficient precaution should be taken to dewater, the forms to allow
concreting in dry condition. In marine condition or in areas exposed to the action
of harmful chemicals, the pile cap shall be protected with a suitable anti-corrosive
paint. High alumina cement, i.e. quick setting cement shall not be used in marine
constructions.(Clause 709.5.4 of IRC:78: 2000 was amended as IRC notification
No: 54 dated 28.05.2009)

1115 IMPORTANT CONSIDERATIONS, INSPECTION/PRECAUTIONS FOR

DIFFERENT TYPES OF PILES
1115.1 Driven Cast-in-Situ Piles
1115.1.1 Specialist literature and the guidelines from the pile construction industry shall be
consulted regarding the method of installation, equipment and accessories for
pile driving and recording of data.
1115.1.2 During installation of piles the final "set" of penetration of pile per blow of hammer
shall be checked taking an average of last 10 blows.
1115.1.3 The pile shoes which may be of either cast iron conical type or mild steel flat type
shall have double reams for proper seating of the removable casing tube inside
the space between the reams.
1115.1.4 Before commencement of pouring of concrete, it shall be ensured that there is no

ingress of water in the casing tube from the bottom. Further adequate control
during withdrawal of the casing tube is essential so as to maintain sufficient head
of concrete inside the casing tube at all stages of withdrawal.
1115.1.5 Concrete in piles shall be cast upto a minimum height of 600 mm above the
designed top level of pile, which shall be stripped off at the time of construction of
pile cap.
1115.2 BORED CAST-IN-SITU PILES
1115.2.1 While concreting uncased piles, voids in concrete shall be avoided and sufficient
head of concrete is to be maintained to prevent inflow of soil or water into the
concrete. It is also necessary to take precautions during concreting to minimise
the softening of the soil by excess water. Uncased cast-in-situ piles shall not be
allowed where mudflow conditions exist.
1115.2.2 The drilling mud such as bentonite suspension shall be maintained at a level
sufficiently above the surrounding ground water level to ensure the stability of the
strata which is being penetrated throughout the boring process until the pile has
been concreted.
1115.2.3 Where bentonite suspension is used to maintain the stability of the bore-hole, it is
essential that the properties of the material! be carefully controlled at stages of

mixing, supply to the bore-hole and immediately before concrete is placed. It is

usual to limit:
i) The density of bentonite suspension to 1.05 g/cc
ii) The marsh cone viscosity between 30 and 40
iii) The pH value between 9.5 and 12
iv) The silt content less than 1 per cent
v) The liquid limit of bentonite not less than 400 per cent
These aspects shall act as controlling factors for preventing contamination of

bentonite slurry for day and silt.
1115.2.4 The bores shall be washed by bentonite flushing to ensure clean bottom at two
stages viz. after completion of boring and prior t6 concreting after placing of
reinforcement cage. Flushing of bentonite shall be done continuously with- fresh
bentonite slurry till the consistency of inflowing and out-flowing slurry is similar.
1115.2.5 Tremie of 150 mm to 200 mm diameter shall be used for concreting. The tremie
should have uniform and smooth cross-section inside, and shall be withdrawn
slowly ensuring adequate height of concrete outside the tremie pipe at all stages
of withdrawal. Other recommendations for tremie concreting are:
(i) The sides of the bore-hole have to be stable throughout
(ii) The tremie shall be water-tight throughout its length and have a hopper
attached at its head by a water-tight connection
(iii) The tremie pipe shall be large enough in relation to the size of aggregates.
For 20 mm aggregate the tremie pipe shall be of diameter not less than 150 mm
and for larger size aggregate tremie pipe of larger diameter is required.
(iv) The tremie pipe shall be lowered to the bottom of the bore-hole, allowing
water or drilling mud to rise inside it before pouring concrete.
(v) The tremie pipe shall always be kept full of concrete and shall penetrate well
into the concrete in the bore-hole with adequate margin of safety against
accidental withdrawal if the pipe is surged to discharge the concrete.

1115.2.6 For very long or large diameter piles, use of retarding plasticiser in concrete is
desirable.
1115.2.7 For large diameter piles, it may be essential to conduct nondestructive pile
integrity tests to evaluate integrity of the pile.
1115.2.8 Where possible, it may be desirable to grout the base of pile with cement slurry
under suitable pressure after concrete in the pile attains the desired strength. For
this purpose, conduit pipes with easily removable plugs at the bottom end should
be placed in the bore along with reinforcement cage before concreting.
1116 TOLERANCES
1116.1 Permissible Tolerances for Pile
i) Precast Concrete Piles:
a) Variation in cross-sectional dimensions : ±5mm
b) Variation in length : ±2Smm
c) Surface irregularities measured with 3 m straight edge : 5mm
d) Bow for length in mm Pile length in mm 1000
ii) Driven Piles
a) Variation in cross-sectional dimensions +50mm, -10mm
b) Variation from vertical or specified rake 1 in 50
c) Variation in the final position of the head in plan 75mm
d) Variation of level of top of piles ±25mm
iii) Bored Piles
a) Variation in cross-sectional dimensions +50mm, -10mm
b) Variation from vertical or specified rake 1 in 50
c) Variation in the final position of the head in plan 50mm
d) Variation of level of top of piles ±25mm
1116.2 Permissible Tolerances for Pile Caps
(a) Variation in dimensions: +50 mm -10 mm
(b) Misplacement from specified position in: 15mm
(c) Surface irregularities measured with 3 m plan straight edge: 5mm

(d) Variation of levels at the top: ±25 mm
1117 TESTS AND STANDARDS OF ACCEPTANCE
The materials shall be tested in accordance with these Specifications
and shall meet the prescribed criteria.
The work shall conform to these Specifications and shall meet the
prescribed standards of acceptance.
1118 MEASUREMENTS FOR PAYMENT
For supply of precast concrete, timber or steel piles of specified cross-section,

the measurement shall be in metres of the length of piles ordered in writing by the
Engineer measured from the head to the butt of the shoe or the tapered point.
Reinforcement. in precast concrete piles shall not be measured for payment.
For cast-In-situ driven and bored concrete piles of specified cross-section, the
measurement shall be the length in metres of the accepted pile that remains in
the finished structure complete in place. Reinforcement in cast-In-situ driven and
bored concrete piles shall be measured for payment as per Section 1600.
Routine and Initial Pile load Tests shall not be measured for payment
For installation of the pile, i.e. by driving in the case of precast concrete, timber,
steel and cast-In-situ driven piles, and by boring in the case of cast-in-situ bored
piles the measurement shall be the length in metres that remains in the finished
structure complete in place, limited to that shown on drawings or ordered by the
Engineer. No distinction shall be made for penetration through hard strata or rock
and socketing into rock.
For steel liners/casing shown on the drawings to be permanently left in place, the
measurement shall be by weight in tonnes that remains in the finished structure
complete in place, limited to that shown on drawings or ordered by the Engineer.
For the pile cap, the quantity of concrete shall be measured in cubic metres as
per Section 1100. While reinforcement in pile cap shall be measured in tonnes as
per Section 1600.

1200 WELL FOUNDATIONS

1201 DESCRIPTION
This work consists of construction of well foundation, taking it down to the

founding level through all kinds of sub-strata, plugging the bottom, filling the
inside of the well, plugging the top and providing a well cap in accordance with
the details shown on the drawing and as per these specifications, or as directed
by the Engineer.
In case of well foundations of size larger than 12 m diameter, supplemental

construction specifications will be necessary.
1202 GENERAL
1202.1 Wells may have a circular, rectangular, or D-shape in plan and may consist of
one, two or more compartments in plan. The outer wall of the well is known as
well steining, which may be cellular.
The process of taking down the well to the founding level is known as well
sinking. After reaching the founding level, the hollow inside the well, ("dredge
hole") is plugged at the bottom by concrete ("bottom plug':). The dredge hole is
then filled with approved filling upto the level indicated on the drawings and
provided with a concrete plug ("top plug").The minimum dimension of the dredge
hole should not be less than 3 m. (Clause 708.1.1 of IRC:78: 2000 was amended
as IRC notification No: 54 dated 28.05.2009)
To facilitate sinking of well, steel cutting edge is fabricated and connected to a

concrete well curb of required shape. On top of the well curb, adequate height of
well steining is cast and the process of sinking is carried out After a portion of the
well has been sunk, another height of well steining is cast on top of the previous
section and further sinking carried out This process is continued till the bottom
level of the well reaches the founding level.
At the top of the well steining, an adequately designed "welt cap" is laid which
transmits the loads and forces from the sub-structure (piers or abutments) to the
foundations.
1202.2 At least one bore-hole must be available/carried out in accordance with these
specifications at each well foundation location, prior to commencement of work.
The depth of bore-holes should extend upto a depth equal to one and a half times
the outer diameter/least dimension of the well below the anticipated founding
level. The results of soil exploration should be presented in accordance with

clause 7.4 of IRC:78. In case the well foundation is to rest on a rocky strata, it
may be necessary to undertake additional borings /probings prior to
commencement of work to ascertain the actual profile and the quality of the rocky
strata, at the level at which the well has to be seated, etc.
1202.3 Blasting may have to be resorted to in order to facilitate sinking through difficult
strata, such as boulders and rocks etc. In case blasting is anticipated,
protective/strengthening measures specified in clause 710.6 (IV) of IRC:78 shall
be taken. The grade of concrete in bottom 3 metres of steining shall not be leaner
than M 20 or as shown on the drawings.
1202.4 In case the bore hole data shows the presence of steeply dipping rock, chiselling
may have to be resorted to so as to obtain proper seating of the foundation. For
this purpose, the well may require to be dewarered completely under high air
pressure inside the well. This process is known as pneumatic sinking. Pneumatic
sinking may also have to be resorted to in cases where obstacles such as tree
trunks, large sized boulders or hard strata etc. cannot be removed by open
dredging. The necessity of adopting pneumatic sinking shall be decided by the
Engineer.
The curb and steining have to be specifically designed for special_ loadings when
pneumatic sinking is adopted.
1203 SETTING OUT AND PREPARATIONS FOR SINKING
1203.1 Necessary reference points shall be fixed, away from the zone of blow-ups or
possible settlements resulting from well sinking operations. Such reference points
shall be connected to the permanent theodolite stations with the base fine on the
banks. The centre of the individual wells shall be marked with reference to these
stations. The distance, wherever practicable, shall be checked with the help of
accurate tapes and precision distomat.
Reference points shall also be fixed to mark X-X axis (usually traffic Direction)
and Y-Y axis (normal to X-X axis) accurately. A temporary bench mark shall also
be established near the well foundation, away from the zones of blow-ups or
possible settlement The bench mark shall be checked regularly with respect to
the permanent bench mark established at the bridge site.
1203.2 For wells which are to be pitched in water, an earthen or sand island shall be
constructed. Sand islands are practicable for water depths of about 5 metres
under stable bed soil conditions. For greater depths or in fast flowing rivers or for

locations where soil is too weak to sustain sand island, floating caissons may
have to be adopted.
The plan dimensions of sand islands shall be such as to have a working space of
at least 2 metres all around the steining. The dimension of the sand islands shall
however be not less than twice the dimension in plan of the well or caisson. Sand
islands shall be maintained to perform their functions, until the well is sunk to a
depth below the bed level at least equal to the depth of water.
Sand island shall be protected against scour and the top level shall be sufficiently
above the prevailing water level to be decided by the Engineer so that it is safe
against wave action.
While sand islands are constructed at well location, floating caissons are
generally fabricated at or near the banks on dry land or dry docks. Floating
caissons are towed into position in floating condition.
Floating caissons may be of steel, reinforced concrete or a combination of the

two. They should have at least 1.5 m free board above water level and increased,
if considered necessary, in case there is a possibility of caissons sinking
suddenly owing to reasons such as scour likely to result from the lowering of
caissons, effect of waves, sinking in very soft strata etc.
Stability of floating caissons shall be ensured against overturning and capsizing

while being towed and during sinking for the action of water current, wave
pressure, wind etc.
For floating caissons, a detailed method statement for fabrication, floating and
sinking of caissons shall be prepared and furnished to the Engineer. Such
statement shall include the total tonnage of steel involved, fabrication and
welding specifications, list of materials and plant and a description of operations
and manpower required for the work. The caisson shall be tested for leakages
before being towed to site.
1203.3 Equipment
Equipment shall be deployed for construction of well foundation as required and

as directed by the Engineer. Generally, the following equipments may be required
for the work;
(aj Crane with grab buckets - capacity 0.5 to 2.0 cum.
(b) Submersible pumps

(c) Air compressors, air locks and other accessories where pneumatic sinking of
well is anticipated.
(d) Chisels of appropriate sizes •
(e) Aqua-header for cutting rocky strata
(f) Diving helmets and accessories
(g) Equipment for concrete production, transportation planning and compaction.

1204 CUTTING EDGE
1204.1 The mild steel cutting edge shall be made from structural steel sections. The
cutting edge shall weigh not less than 40 kg per metre length and be properly
anchored into the well curb, as shown in the drawing. When there are two or
more compartments in a well, the bottom end of the cutting edge of the inner
walls of such wells shall be kept at about 300 mm above that of outer walls.
1204.2 The parts of cutting edge shall be erected on level firm ground. Temporary
supports shall be provided to facilitate erection and maintaining the assembly in
true shape. The fabrication may be carried out in the shop or at site. Steel
sections shall not be heated and forced into shape. However, "V" cuts may be
made in the horizontal portion, uniformly throughout the length, to facilitate cold
bending. After bending, such "V" cuts should be dosed by welding. Joints in the
lengths of structural sections, unless otherwise specified shall be fillet welded
using single cover plate to ensure the requisite strength of the original section.
1204.3 The cutting edge shall be laid about 300 mm above prevalent water level.
1205 Well CURB
1205.1 The well curb may be precast or cast-in-situ. Steel formwork for well curb shall be
fabricated strictly in conformity with the drawing. The outer face of the curb shall
be vertical. Steel reinforcements shall be assembled as shown on the drawings.
The bottom ends of vertical bond rods of steining shall be fixed securely to the
cutting edge with check nuts or by welds.
1205.2 The formwork on outer face of curb may be removed within 24 hours after
concreting. The formwork on inner face shall be removed after 72 hours.
1205.3 All concreting in the well curb shall be done in one continuous operation.
1206 WELL STEINING
1206.1 The dimensions, shape, concrete strength and reinforcements of the well shall
strictly conform to those shown on the drawings. The form work shall preferably
be of M.S. sheets shaped and stiffened suitably. In case timber forms are used,
they shall be lined with plywood or M.S. sheets.
1206.2 Steining built in the first lift above the well curb shall not be more than 2 metres
and in subsequent lifts it shall not exceed the diameter of the well or the depth of
well sunk below the adjoining bed level at any time. For stability, the first lift of
steining shall be cast only after sinking the curb at least partially for stability.

Concreting of steining may be carried out in subsequent lifts of about 2 to 2.5

metres. Attempts should be made to minimise the number of construction joints.
The concreting layers shall be limited to about 450 mm restricting the free fall of
concrete to not more than 1.5 m. laitance formed at the top surface of a lift shall
be removed to expose coarse aggregates before setting of concrete at the
proposed construction joint As far as possible, construction joints shall not be
kept at the location of laps in the vertical steining bars.
1206.3 The steining of the well shall be built in one straight line from bottom to top such
that if the well is tilted, the next lift of steining will be aligned in the direction of the
tilt The work will be checked carefully with the aid of straight edges of lengths
approved by the Engineer. Plumb bob or spirit level shall not be used for
alignment After sinking of a stage is complete, damaged portions if any, of
steining at top of the previous stage shall be properly repaired before
constructing the next stage.
1206.4 The height of steining shall be calibrated by making at least 4 gauges (preferably
in traffic direction and in a direction normal to traffic direction) distributed equally
on the outer periphery of the well each in the form of a 100 mm wide strip painted
on the well, with every metre mark shown in black paint. The gauges shall start
with zero at the bottom of the cutting edge. Marking of the gauges shall be done
carefully with a steel tape.
1206.5 After reaching the founding level, the well steining shall be inspected to check for
any damage or cracks. The Engineer will direct and the Contractor shall execute
the remedial measures before acceptance of the well steining. In case the well
cannot be accepted even with any remedial measures, then the well shall stand
rejected.
1207 WELL SINKING
1207.1 General
The well shall as far as possible be sunk true and vertical through all types of
strata.
Sinking or loading of the well with kentledge shall be commenced only after the
steining has been cured for at least 48 hours or as specified in the drawings
No well shall be permitted to be placed in a pre-dredged hole.

The well shall be sunk by excavating material uniformly from inside the dredge
hole. Use of water jetting, explosives and divers may be adopted for sinking of
wells through difficult strata with prior approval of the Engineer.
Normally dewatering of well should not be permitted as a means for sinking the
well. It also shall never be resorted to if there is any danger of blowing under the
well. Dewatering shall however be done when well is to be founded into rock.
Pneumatic sinking may have to be resorted to where obstacles such as tree
trunks, large size boulders, etc. are met at the bottom or when there is hard strata
which cannot be removed by open dredging. The necessity for pneumatic sinking
shall be decided by the Engineer.
Sinking history of well shall be maintained in the format given in Appendix

1200/1.
1207.2 Use of Kentledge as Sinking Load
Kentledge shall be placed in an orderly and safe manner on the loading platform
and in such a way that it does not interfere with the excavation of the material
from inside the dredge hole and also does not in any way damage the steining of
the well.
Where tilts are present or there is a danger of well developing a tilt, the position
of the load shall be regulated in .such a manner as to provide greater sinking
effort on the higher side of the well.
1207.3 Use of Water Jetting
Water jetting may be employed for well sinking wherever necessary.
1207.4 Use of Explosives
Mild explosive charges may be used as an aid for sinking of the well only with
prior permission of the Engineer. Blasting of any sort shall only be done in the
presence of the Engineer and not before the concrete in the steining has
hardened sufficiently and is more than 7 days old. When likelihood of blasting is
predicted in advance, protection of the bottom portion of the well shall be done as
per these specifications. After blasting operations are completed, the well curb
and steining should be examined for any cracks and remedial measures taken.
If blasting has been used after the well has reached the design foundation level,
normally 24 hours shall be allowed to lapse before the bottom plug is laid.

The charges shall be exploded well below the cutting edge by making a sump so
as to avoid chances of any damage to the curb or to the steining of the well. A
minimum sump of 1 metre depth should be made before resorting to blasting.
Use of large charges, 0.7 kg or above, may not be allowed except under expert
direction and with the permission from the Engineer.
Suitable pattern of charges may be arranged with delay detonators to reduce the
number of charges fired at a time. The burden of the charge may be limited to 1
metre and the spacing of holes may normally be kept as 0.5 to 0.6 metres.
All prevalent laws concerning handling, storing and using of explosives shall be
strictly followed.
All safety precautions shall be taken as per IS:4081 "Safety Code for Blasting and
related Drilling Operations", to the extent applicable, whenever blasting is
resorted to.
There should be no equipment inside the well nor shall there be any labour in the
dose vicinity of the well at the time of exploding the charges.
If rock blasting is to be done for the well, the damage caused by flying debris
should be minimized by covering blasting holes by rubber mates before blasting
1207.5 Use of Divers
Use of divers may be made both for sinking purpose like removal of obstructions,
rock blasting and for inspection. All safety precautions shall be taken as per any
acceptable safety code for sinking with divers or any statutory regulations in
force.
They shall work under expert supervision. The diving and other equipments shall
be acceptable standard and certified to this effect by an approved independent
agency. It shall be well maintained for safe use.
Arrangement for ample supply of low pressure clean cool air shall be ensured,
through an armoured flexible hosepipe. Standby compressor
Separate high pressure connection for use of pneumatic tools shall be made.
Electric lights where provided shall be at 50 volts (maximum). The
raising of the driver from the bottom of wells shall be controlled so that
decompression rate conforms to the rate as-laid down in appropriate regulations.

1207.6 Use of Pneumatic Sinking
1207.6.1 General
The Engineer shall familiarise himself with, particular. reference to caisson

diseases and working of the medical air-Iock. A doctor competent to deal with
cases of "Caisson Diseases or other complications arising as a result of working
under high pressure, shall be stationed at the construction site when pneumatic
sinking is under progress.
The contractor shall provide complete facilities including the issuing of orders to
ensure strict reinforcement of the requirements outlined in these specifications.
Safety provisions as contained in IS:4138 and in these specifications shall be

strictly followed:
Pneumatic sinking shall be restricted to a depth of 30.0 m.
1207.6.2 Man-locks and Shafts
Locks, reducers, and shaft used in connection. with caissons shall be of riveted
construction throughout. The material used in their manufacture shall be steel
plate with thickness not less than 6 mm.
Shafts shall be subjected to hydrostatic or air pressure test of at least 0.5 MPa,
at which pressure they shall be tight. The pressure at which testing has been
done shall be clearly and visibly displayed.
Shafts shall be provided, with a safe, proper and suitable staircase for its entire
length including landing platforms which are not more than 6 metres apart.
Where this is impracticable due to space constraint, suitable ladders along with
landing platforms shall be installed. These shall be kept dear and in good
condition at all times and shall be constructed, inspected and maintained to the
entire satisfaction of the Engineer.
A 1.0 m wide platform with 1.0 m high railing shall be provided all round the
caisson air-locks.
Where 15 or more men are employed, caissons shall have two locks, one of
which shall be used as a man lock.
Locks shall be located so that the lowest part of the bottom door shall not be less
than 1 metre above high water level.

The supply of fresh air to the working chamber shall at all times be sufficient to
permit work to be done without any danger or excessive discomfort. All air
supply lines shall be supplied with check valves and carried as near to the face
as practicable.
A man-lock shall be used solely for the compression or decompression of

persons, and not for the passage of plant and material and shall be maintained in
a reasonably clean and sufficiently warm state of the work may be carried into the
man-lock.
Where it is not reasonably practicable to provide a separate man-lock for use by

persons only, the lock when it is in actual use for compression or decompression
of a person or persons shall not be put, simultaneously, to any other use and
shall be in a reasonably clean and sufficiently warm state.
1207.6.3 Values
Exhaust valves shall be provided, having risers extending to the upper part of the
chamber. These shall be operated, whenever necessary specially after a blast
until the gas and smoke are cleared.
1207.6.4 Medical supervision and certification
Every employee absent from work for 10 or more consecutive days due to illness
or any other disability shall be required to pass the regular physical examination
by the doctor before being permitted to return to work.
After a person has been employed continuosly in compressed air for a period of
two months, he shall be re-examined by the doctor and shall not be permitted to
work until such re-examination has been made and the report is satisfactory.
No person known to be addicted to the excessive use of intoxicants hall be

permitted to work in compressed air.
The doctor shall, at all times, keep a complete and full record of examinations
made by him, which shall contain dates of examinations, a clear and full
description of the person examined, his age and physical condition at the time of
examination and a statement as to the period such a person has been engaged
in such employment records shall be kept at the place where the work is in
progress and shall be subject to inspection by authorised officers.
Every man lock shall always have a doctor or e responsible person in

attendance. In case the person in charge is not a doctor he must have positive

means of promptly communicating with and securing the service of a competent

doctor in case of emergency. Such arrangements shall invariably be subject to
the approval of the Engineer.
If the air pressure exeeds 0.2 MPa gauge or if 50 or more men are employed, it is
obligatory for the person in charge of medical lock to be a doctor experienced in
this type of work.
All case of compressed-air illness shall be reported and copies of all such reports
shall be kept on file at the place of work.
1207.6.5 Lighting
All lighting in compressed air chambers shall be operated only by electricity. Two
independent electric lighting system with independent sources of,supply shall
become automatically operative in case of failure of regularly used source.
The minimum intensity of light on any walkway ladder, stairway, or lower working
level shall be one-quarter (1/4) candlepower. In all work places, the lighting shall
always be such as to enable workmen to see their way about clearly All external
parts of lighting fixtures and electrical equipment lying within 2.5 meters above
the floor shall be constructed of non-combustible, non absorbing insulating
materials. If metal is used it must be effectively earthed. Portable lamp shall have
non-combustible, non- absorbing insulating sockets, approved handles, basket
guards and approved cables. The use of worn or detective portable and pendant
conductors, shall be prohibited.
1207.6.6 Safety against fire hazard
No oil, gasoline, or other combustible material shall be stored within 30 metres of

any shaft, caisson, or tunnel opening. However, oil may be stored in suitable
tanks in isolated fireproof buildings, provided such buildings are not less than 15
metres from any shaft, caisson, or tunnel opening or any building directly
connected thereto.
Positive means shall be taken to prevent leaking flammable liquids from flowing
into areas specifically mentioned in the preceding paragraph. Where feasible, a
fire hose connected to a suitable source of water shall be provided at the top of
every caisson. Where fire mains are not accessible, a supply of water shall be
stored in tanks near the top of every caisson, provided fire pails or suitable
pumps are kept available. Approved fire extinguishers shall also be provided.

1207.6.7 Sanitation
Properly heated, lighted and ventilated .dressing rooms shall be provided for all
employees engaged in compressed air work. Such rooms shall contain lockers
and benches and be open and accessible to men during intermission between
shifts. Adequate toilet accommodation of one for every twenty five employees
shall be provided.
Care shall be taken to keep all parts of the caissons and other working
compartments, including locker rooms, dry rooms, rest rooms, and other
equipment in a good sanitary condition and free from refuse, decaying, or other
objectionable matter.
No nuisance shall be tolerated in the air chamber. Smoking shall be strictly

prohibited and all matches and smoking materials shall be left out of the locker
rooms.
A separate dry-room shall be provided where working clothes may be dried within
reasonable time.
1207.6.8 Protection against gases
In all cases where gas is expected including alluvium impregnated with decayed
vegetable matter the use of Davy Safety lamp shall be compulsory.
1207.6.9, Additional safety provisions
a) The weight of the pneumatic platform and that of steining and kentledge, if
any, shall be sufficient to resist the uplift from air inside, skin friction being
neglected in this case. If, at any section the total weight acting downwards is less
than the uplift pressure of air inside, additional kentledge shall be placed on the
well.
If it is not possible to make the well heavy enough during excavation, "blowing
down" may be used The men should be withdrawn and air pressure reduced. The
well should then begin to move with small reduction in air pressure. "Blowing
down" should only be used when the ground is such that it will not heave up
inside the chamber when the pressure is reduced. When the well does not move
with the reduction in air pressure, kentledge should be added. "Blowing down"
should be in short stages and the drop should not exceed, 0.5 metre at any
stage. To control sinking during blowing down, use of packings are
recommended.

b) The pneumatic sinking plant and other allied machinery shall not only be of
proper design and make, but also shall be worked by competent and well trained
personnel. Every part of the machinery and its fixtures shall be minutely
examined before installation and use. Availability of appropriate spares,
standbys, safety of personnel as recommended 15:4138 for working in
compressed air must be ensured at site. Codes for safety and for working in
compressed air and other labour laws and practices prevalent in the country, as
specified to provide safe, efficient and expeditious sinking shall be followed.
c) Inflammable materials shall not be taken into air locks and smoking shall be
prohibited. Wherever gases are suspected to be issuing out of dredge hole, the
same shall be analysed by trained personnel and necessary precautions adopted
to avoid hazard to life and equipment. d) Where blasting is resorted to, it shall be
carefully controlled and all precautions regarding blasting shall be observed,
Workers shall be allowed inside after blasting only when a competent and
qualified person has examined the chamber and steining thoroughly and found
the same to be safe.
1207.7 Precautions During Sinking
a) When the wells have to be sunk dose to each other and dear distance
between them is not greater than the diameter of wells, sinking shall be taken up
on all wells and they shall be sunk alternately so that sinking of wells proceeds
uniformly. Simultaneous and even dredging shall be carried out in the wells in
such a manner that the difference in the levels of the sump and curling edge in
the adjacent wells does not exceed half the dear gap between them. Plugging of
all the wells shall be done together..
b) During sinking of dumb-bell or double D-shaped wells, the excavation in both

the dredge holes should be carried out simultaneously and equally.
c) Bore chart shall be referred to constantly during sinking for taking adequate
care while piercing different types of strata. The type of soil as obtained during
the well sinking should be compared with bore chart so as to take prompt
decisions;
d) Before seasonal floods all wells on which sinking is in progress shall be sunk
to sufficient depths below the designed scour level. Further, they shall be
temporarily filled and plugged so that they do not suffer any tilt or shift during the
floods.

e) All necessary precautions shall be taken against any possible damage to the
foundations of existing structures in the vicinity of the wells, prior to
commencement of dredging from inside the well.
f) The dredged material shall not be allowed to accumulate over the well. It shall
be dumped and spread, as far away as possible, and then continuously and
simultaneously removed, as directed by the Engineer. In case the river stream
flows along one edge of the well being sunk, the dredged material shall not be
dumped on the dry side of the bank but on the side on which the river current
flows.
g) Very deep sump shall not be made below the well curb, as it entails risk of
jumping (sudden sinking) of the well. The depth of sump shall be generally limited
to one-sixth of the outer diameter/least lateral dimension of the well in plan.
Normally, the depth of sump shall not exceed 3.0 metres below the level of the
cutting edge unless otherwise specifically permitted by the Engineer.
h) In case a well sinks suddenly with a jerk, the steining of the well shall be
examined to the satisfaction of the Engineer to see that no damage has occurred
to it.
i) In pneumatic sinking, the well shall not, at any time, be dropped to a depth
greater than 500 mm by the method of "blowing down".
j) Dewatering shall be avoided if sand blows are expected. Any equipment and
men working inside the well shall be brought out of the well as soon as there are
any indications of a sand-blow.
k) Sand blowing in wells can often be minimised by keeping the level of water
inside the well higher than the water table and also by adding heavy kentledge,
I) In soft strata prone to settlement/creep, the construction of the abutment wells

shall be taken up only after the approach embankment for a sufficient distance
near the abutment has been completed.
1207.8 Tilts and Shifts
The inclination of the well from the vertical is known as tilt and the horizontal
displacement of the centre of the well at the founding level from its theoretical
position is known as shift.

Unless otherwise specified, the tilt of any well shall not exceed 1 (horizontal) in
80 (vertical), and the shift at the well base shall not be more than 150 mm in any
resultant direction.
Tilts and shifts shall be carefully checked and recorded in the format vide
Appendix 1200/H regularly during sinking operations. For the purpose of
measuring the tilts along the two axes of the bridge, reduced level of the marks
painted on the surface of the steining of the well shall be taken. For determination
of shift, locations of the ends of the two diameters shall be precisely measured
along the two axes, with reference to fixed reference points.
Whenever any tilt is noticed, adequate preventive measures like placing eccentric
kentledge, pulling, strutting, anchoring or dredging unevenly and depositing
dredge material unequally, putting obstacles below cutting edge. Water jetting
etc., shall be adopted before any further sinking. After correction, the dredged
material shall be spread out uniformly.
A pair of wells close to each other have a tendency to come closer while sinking.
Timber struts may be introduced in between the steining of these wells to prevent
tilting.
Tilts occurring in a well during sinking in dipping rocky strata can be safeguarded
by suitably supporting the curb.
In the event of a well developing tilt or shift beyond the specified permissible
values, the Contractor shall have to carry out, :at his own cost, suitable remedial
measures to the satisfaction of the Engineer, to bring the tilt and shift within
permissible values, as far as practicable .
If the resultant tilt and I or shift of any well exceeds the specified permissible
values, generally it should not exceed 1 in 50 and 300 mm respectively. The well
so sunk shall be regarded as not conforming to specifications and a sub-standard
work. The Engineer in his sole discretion, may consider accepting such a well,
provided:
(i) Calculations for foundation pressures and steining stresses, accounting for the
actual tilt and shift furnished by the Contractor show that the well is safe. Any
remedial measures required to bring the stresses within permissible values (such
as increase in the dimension of the well cap, provision of dummy weights on the
well cap etc}, shall be carried out by the Contractor without claiming for any extra
cost

(ii) The Contractor shall agree to reduction in rates in accordance with Clause
1215(g).
In case the Engineer, in his discretion, rejects the well, the Contractor shall
dismantle the rejected well to the extent directed by the Engineer and remove the
debris. Further, the Contractor shall, at his own risk and expense complete the
bridge with modified span arrangement acceptable to the Engineer.
1207.9 Seating of Wells
The well shall be uniformly seated at the founding strata. It shall be ensured by
test borings that the properties of the soil encountered at the founding strata and
upto a depth of one and a half times the well diameter is identical to that adopted
in the design. The procedure for test borings shall satisfy the provisions of these
specifications. In case the soil encountered is inferior to that adopted in design,
the well shall be re-designed by the Engineer adopting the soil properties actually
encountered and the founding level intimated to the Contractor, who shall carry
out the work.
In case of seating of wells in hard rocky strata, where the rock profile is steeply
sloping, pneumatic methods of sinking may be adopted to seat the well evenly as
directed by the Engineer. The decision of adopting pneumatic sinking shall be
taken by the Engineer. The cutting edge may also be embedded for a suitable
depth in the rocky strata, as decided by the Engineer keeping in view the quality
of rock. As an additional measure of safety, the well shall be anchored to the
rocky strata by anchor bars provided in the steining of the well, as shown on the
drawing irrespective of the fact that tension develops or not at the base of the
well under design loads. After the well has been evenly seated on good hard
rock, arrangements shall be made to facilitate proper inspection in dry and visible
conditions before the bottom plug is laid.
1208 BOTTOM PLUG
For bottom plug, the concrete mix shall be designed (in dry condition) to attain
the concrete strength as mentioned on the drawing and shall contain 10 per cent
more cement than that required for the same mix placed dry, to cater for
underwater concreting. However, the total cement content shall not be less than
363 kg/cu.m. of concrete with a slump in the range of 150 mm to 200 mm.
Admixtures may be added to the concrete to impart the required characteristics
indicated herein.

Concrete for the bottom plug shall be laid by tremie pipe method. Tremie
concrete when started shall be continued without interruption for full concreting in
the bottom plug. The concrete production equipment and placement equipment
should be sufficient to enable under water concreting within stipulated time.
Necessary standby equipment should be available for emergency situation.
Before commencing plugging, all loose material from the bottom of the well shall
be removed.
Concreting shall be done in one continuous operation till the dredge hole is filled
upto the required height and thereafter sounding shall be taken upto ensure that
the concrete has been laid to the required height.
Least disturbance shall be caused to the water inside the well [ while laying
concrete in the bottom plug].
Concrete shall not be disturbed in any way for at least 14 days. In order to check
any rise in the level of the bottom plug soundings should be taken at the dose of
concreting and once every day for the subsequent 3 days.
The soundness of the bottom plug may be tested by dewatering the well by 5
metres below the surrounding water level and checking the rise of water. The rate
of rise shall preferably be less than 10 cms I per hour. In case the the rate is
higher, suitable remedial measures as directed by the Engineer, shall be taken by
the Contractor at his own cost.
1209 SAND FILLING
Sand filling shall commence after a period of 3 days of laying of bottom plug.
Also, the height of the bottom plug shall be verified before starting sand filling.
Sand shall be clean and free from earth, clay clods, roots, boulders, shingles, etc.
and shall be compacted as directed. Sand filling shall be carried out upto the
level shown on the drawing, or as directed by the Engineer.
1210 TOP PLUG
After filling sand upto the required level a plug of concrete shall be provided over
it as shown on the drawing, or as directed by the Engineer.
1211 WELL CAP
A reinforced cement concrete well cap will be provided over the top of the
steining in accordance with the drawing. Formwork will be prepared conforming
to the shape of well cap. Concreting shall be carried out in dry condition. A

properly designed false steining may be provided where possible to ensure that
the well cap is laid in dry conditions.
The bottom of the well cap shall be laid preferably as low as possible, taking
account the water level prevalent at the time of casting. Bond rods of steining
shall be anchored into the well cap.
1212 TOLERANCES
The permissible tilt and shift shall not exceed 1 (horizontal) in 80 (vertical) and
the shift at the well base shall not be more than 150 mm in any resultant
direction.
For the well steining and well cap the permissible tolerances shall be as follows:
a) Variation in dimension +50 mm -10mm
b) Misplacement from specified position in plan 15mm
c) Surface irregularities measured with 3 m straight edge 5 mm
d) Variation of levels at the top ±2Smm
The materials shall be tested in accordance with these Specifications and shall
meet the prescribed criteria.
The work shall conform to these Specifications and shall meet the prescribed
standards of acceptance.
All quantities shall be measured from the drawing, or as ordered by the Engineer,
excepting those required to be provided by the Contractor at his cost.
a) The cutting edge shall be measured in tonnes based on the net weight of
metal used in it, as per Section 1900.
b) The concrete in curb, well steining and well cap shall be measured in cubic
metres in each of the items as per Section 1700. The reinforcements shall be
measured in tonnes separately in each of the items, as per Section 1600.
c) The measurement for well sinking shall be made in running metres for different
depths and in different types of strata (for example, predominantly sand/ clay soil,
soft rock, hard rock, etc) as specified in the Contract The depth of Sinking shall
be measured from the level specified in the Contract. If no level has been

specified in the Contract, sinking shall be measured from the low water level or
from the level at which the cutting edge was laid, whichever is higher.
d) The quantity of concrete in bottom and top plug shall be measured in cubic
metres as per Section 1700.
e) The quantity of sand filling shall be measured in cubic metres.
f) Pneumatic sinking, where required shall be paid as a separate item and shall
be measured b cubic metres of material to be excavated.
1215 RATE
a) The Contract unit rates of cutting edge shall cover all costs of labour, material,
tools, plant and equipment, including placing in position, sampling and testing,
and, supervision, all as per respective Section of Structural Steel Work and as
described in this section.
b) The Contract unit rates for concrete in curb, steining, bottom plug, top plug and
well cap, shall cover all costs of labour, material, tools, plant and equipment, form
work and staging including placing in position, sampling and testing, and,
supervision, all as per respective Section of Structural Concrete and as described
in this section.
c) The Contract unit rates for reinforcement in curb, steining, and well cap, shall
coverall costs of labour, material, tools, plant and equipment, including bending to
shape, placing in position, sampling, testing and supervision, all as per respective
Section of Steel Reinforcement and as described in this section.
d) The Contract unit rates for sand filling shall cover all costs of labour, material,
tools, plant and equipment, including placing in position, sampling, testing and
supervision, all as described in this section.
e) The Concrete unit rates for sinking shall cover the costs of labour, tools, and
equipment and plant and for all operations and other incidentals for sinking of
well including seating excepting provisions of pneumatic sinking as described in
this Section. The unit rates shall specify the strata such as types of soil, rock, etc.
The rate shall cover all testing and supervision required for the work.
f) The Contract unit rate of material to be excavated by pneumatic sinking shall

cover all costs of labour, material, tools, plant and other equipment and other
incidentals and safety provisions and supervision required for pneumatic Sinking
as per this Section.

Reduction in contract unit rates for sinking as a penalty, in pursuance of clause

1207.8.
If any well with tilt and/or shift exceeding beyond permissible values is accepted
by the Engineer, the Contractor shall give a reduction in the rates as follows:
TABLE 1200-1 REDUCTION IN RATES
percent deduction on the

S.No Amount of tilt and/or shift rate(sl for sinking of Whole
well
Tilt exceeding the specified
1 permissible value but equal to or 5 percent
within 1 in 60
Tilt exceeding 1 in 60 but equal to
2 10 percent
or within 1 in 50
3 Tilt exceeding 1 in 50 20 percent
Shut exceeding the specified
4 permissible value but equal to or 2 percent
within 200 mm
Shift exceeding 200 mm but equal
5 5 percent
to or within 300 mm
6 Shift exceeding 300 mm 10 percent
Penalties for excessive tilt and shift shall be deducted separately.

1300 BRICK MASONRY

1301 DESCRIPTION
This work shall consist of construction of structures with bricks jointed together by
cement mortar in accordance with the details shown on the drawings or as
1302 MATERIALS
All materials to be used in the work shall conform to the requirements laid down
in Section 1000.
1303 PERSONNEL
Only trained personnel shall be employed for construction and supervision.
1304 CEMENT MORTAR
Cement and sand shall be mixed in specified proportions given in the drawings.
Cement shall be proportioned by weight, taking the unit weight of cement as 1.44
tonne per cubic metre. Sand shall be proportioned by volume taking into account
due allowance for bulking. All mortar shall be mixed with a minimum quantity of
water to produce desired workability consistent with maximum density of mortar.
The mix shall be dean and free from injurious type of soil/acid/alkali/ organic
matter or deleterious substances.
The mixing shall preferably be done in a mechanical mixer operated manually or

by power. Hand mixing can be resorted to as long as uniform density of the mix
and its strength are assured subject to prior approval of the Engineer. Where
permitted, specific permission is to be given by the Engineer. Hand mixing
operation shall be carried out on a dean water-tight platform, where cement and
sand shall be first mixed dry in the required proportion by being turned over and
over, backwards and forwards several times till the mixture is of uniform colour.
Thereafter, minimum quantity of water shall be added to bring the mortar to the
consistency of a stiff paste.
The mortar shall be mixed for at least two minutes after addition of water. Mortar
shall be mixed only in such quantity as required for immediate use. The mix
which has developed initial set shall not be used. Initial set of mortar with ordinary
Portland Cement shall normally be considered to have taken place in 30 minutes
after mixing. In case the mortar has stiffened during initial setting time because of
evaporation of water, the same can be re-tempered by adding water as frequently

as needed to restore the requisite consistency, but this re-tempering shall not be
permitted after 30 minutes. Mortar unused for more than 30 minutes shall be
rejected and removed from site of work.
1305 SOAKING OF BRICKS
All bricks shall be thoroughly soaked in a tank filled with water for a minimum
period of one hour prior to being laid. Soaked bricks "shall be removed from the
tank sufficiently in advance so that they are skin dry at the time of actual laying.
Such soaked bricks shall be stacked on a dean place where they are not
contaminated with dirt, earth, etc.
1306 JOINTS
The thickness of joints shall not exceed 10mm. All joints on exposed
faces shall be tooled to give concave finish.
1307 LAYING
All brickwork shall be laid in an English bond, even and true to line, in accordance
with the drawing or as directed by the Engineer, plumb and level and all joints
accurately kept. Half and cut bricks shall not be used except when necessary to
complete the bond. Closer in such cases shall be cut to the required size and
used near the ends of the walls. The bricks used at the face and also at all angles
forming the junction of any two walls shall be selected whole bricks of uniform
size, with true and rectangular faces.
All bricks shall be laid with frogs up on a full bed of mortar except in the case of
tile bricks. Each brick shall be properly bedded and set in positioned l by slightly
pressing while laying, so that the mortar gets into all their surface pores to ensure
proper adhesion. All head I and side joints shall be completely filled by applying
sufficient mortar to brick already placed and on brick to be placed. All joints shall
be properly flushed and packed with mortar so that no hollow spaces are left. No
bats or cut bricks shall be used except to obtain dimensions of the different
courses for specified bonds or wherever a desired shape so requires.
The brick work shall be built in uniform layers, and for this purpose wooden
straight edge with graduations indicating thickness of each course including joint
shall be used. Corners and other advanced work shall be raked back. Brickwork
shall be done true to plumb or in specified batter. All courses shall be laid truly
horizontal and vertical joints shall be truly vertical. Vertical joints in alternate
courses shall come directly one over the other. During construction, no part of

work shall rise more than one metre above the general construction level, to
avoid unequal settlement and improper jointing. Where this is not possible in the
opinion of the Engineer, the works shall be raked back according to the bond
(and not toothed) at an angle not steeper than 45 degrees with prior approval of
the Engineer. Toothing may also be permitted where future extension is
contemplated;
Before laying bricks in foundation, the foundation slab shall be thoroughly

hacked, swept clean and wetted. A layer of mortar not less than 12 mm thick
shall be spread on the surface of the foundation slab and the first course of bricks
shall be laid.
1308 JOINTING OLD AND NEW WORK
Where fresh masonry is to join with masonry that is partially/entirely set, the
exposed jointing surface of the set masonry shall be cleaned, roughened and
wetted, so as to effect the best possible bond with the new work. All loose bricks
and mortar or other material shall be removed.
In the case of vertical or inclined joints, it shall be further ensured that proper
bond between the old and new masonry is obtained by interlocking the bricks.
Any portion of the brickwork that has been completed shall remain undisturbed
until thoroughly set.
In case of sharp corners specially in skew bridges, a flat cutback of 100 mm shall
be provided so as to have proper and bonded laying of bricks.
1309 CURING
Green work shall be protected from rain by suitable covering and shall be kept
constantly moist on all faces for a minimum period of seven days. Brick work
carried out during the day shall be suitably marked indicating the date on which
the work is done so as to keep a watch on the curing period. The top of the
masonry work shall be left flooded with water at the close of the day. Watering
may be done carefully so as not to disturb or wash out the green mortar.
During hot weather, all finished or partly completed work shall be covered or
wetted in such a manner as will prevent rapid drying of the brickwork.
During the period of curing of brick work, it shall be suitably protected from all
damages. At the close of day's work or for other period of cessation, watering and
curing shall have to be maintained. Should the mortar perish i.e. become dry,
white or powdery through neglect of curing, work shall be pulled down and rebuilt

as directed by the Engineer. If any stains appear during watering, the same shall
be removed from the face.
1310 SCAFFOLDING
The scaffolding shall be sound, strong and safe to withstand all loads likely to
come upon it. The holes which provide resting space for horizontal members
shall not be left in masonry under one metre in width or immediately near the
skew backs of arches. The holes left in the masonry work for supporting the
scaffolding shall be filled and made good. Scaffolding shall be got approved by
the Engineer. However, the Contractor shall be responsible for its safety.
1311 EQUIPMENT
All tools and equipment used for mixing, transporting and laying of mortar and
bricks shall be clean and free from set mortar, dirt or other injurious foreign
substances.
1312 FINISHING OF SURFACES
1312.1 General
All brickwork shall be finished in a workmanlike manner with the thickness of

joints, manner of striking or tooling as described in these above specifications.
The surfaces can be finished by "jointing" or "pointing" or by "plastering" as given

in the drawings.
For a surface which is to be subsequently plastered or pointed, the joints shall be

squarely raked out to a depth of 15 mm, while the mortar is still green. The raked
joints shall be well brushed to remove dust and loose particles and the surface
shall be thoroughly washed with water, cleaned and wetted.
The mortar for finishing shall be prepared as per Clause 1304.
1312.2 Jointing
In jointing, the face of the mortar shall be worked out while still green to give a
finished surface flush with the face of the brick work. The faces of brick work shall
be cleaned to remove any splashes of mortar during the course of raising the
brick work.
1312.3 Pointing
Pointing shall be carried out using mortar not leaner than 1:3 by volume of
cement and sand or as shown on the drawing. The mortar shall be filled and

pressed into the raked joints before giving the required finish. The pointing shall
be ruled type for which it shall, while still green, be ruled along the centre with
half round tools of such width as may be specified by the Engineer. The super
flush mortar shall then be taken off from the edges of the lines and the surface of
the masonry shall be cleaned of all mortar. The work shall conform to IS:2212.
1312.4 Plastering
Plastering shall be done where shown on the drawing. Superficial plastering may
be done, if necessary, only in structures situated in fast flowing rivers or in
severely aggressive environment
Plastering shall be started from top and worked down. All putlog holes shall be
properly filled in advance of the plastering while the scaffolding is being taken
down. Wooden screeds 75 mm wide and of the thickness of the plaster shall be
fixed vertically 2.5 to 4 metres apart, to act as gauges and guides in applying the
plaster. The mortar shall be laid on the wall between the screeds using the
plaster's float and pressing the mortar so that the raked joints are properly filled.
The plaster shall then be finished off with a wooden straight edge reaching
across the screeds. The straight edge shall be worked on the screeds with a
small upward and sideways motion 50 mm to 75 mm at a time. Finally, the
surface shall be finished off with a plasterer's wooden float Metal floats shall not
be used.
When recommencing the plastering beyond the work suspended earlier, the
edges of the old plaster shall be scrapped, cleaned and wetted before plaster is
applied to the adjacent areas.
No portion of the surface shall be left unfinished for patching up at a later period.
The plaster shall be finished true to plumb surface and to the proper degree of
smoothness as directed by the Engineer.
The average thickness of plaster shall not be less than the specified thickness.
The minimum thickness over any portion of the surface shall not be less than the
specified thickness by more than 3 mm.
Any cracks which appear in the surface and all portions which sound hollow when
tapped, or are found to be soft or otherwise defective, shall be cut in rectangular
shape and re-done as directed by the Engineer.

1312.5 Curing of Finishes
Curing shall be commenced as soon as the mortar used for finishing has
hardened sufficiently not to be damaged during curing. It shall be kept wet for a
period of at least 7 days. During this period, it shall be suitably protected from all
damages.
1312.6 Scaffolding for Finishes
Stage scaffolding shall be provided for the work. This shall be independent of the
structure.
1313 ARCHITECTURAL COPING FOR WING/RETURN/PARAPET WALL
This work shall consist of providing an Architectural coping for

wing/retum/parapet walls.
The material used shall be cement mortar 1:3 or as shown on the drawings
prepared in accordance with Clause 1304.
The cement mortar shall be laid evenly to an average thickness of 15 mm to the

full width of the top of the wall and in continuation a band of 15 mm thickness and
150 mm depth shall be made out of the mortar along the top outer face of the
walls.
1314 ACCEPTANCE OF WORK
All work shall be true to the lines and levels as indicated on the drawing or as
directed by the Engineer, subject to tolerances as indicated in these
specifications.
Mortar cubes shall be tested in accordance with IS:1150 for compressive

strength, consistency of mortar and its water retentivity. The frequency of testing
shall be one sample for every 2 cubic metres of mortar, subject to a minimum 3
samples for a day's work.
In case of plaster finish, the minimum surface thickness shall not be less than the
specified thickness by more than 3mm.
All brick work shall be measured in cubic metres. Any extra work done by the
Contractor over the specified dimensions shall be ignored.
In arches, the length of arch shall be measured as the mean length between the
extrados and intrados.

The work of plastering and pointing shall be measured in square metres of the
surface treated.
Architectural coping shall be measured in linear metres.
1316 RATE
The contract unit rate for brick work shall include the cost of all labour, materials,
tools and plant, scaffolding and other expenses incidental to the satisfactory
completion of the work, sampling, testing and supervision as described in these
specifications and as shown on the drawings.
The contract unit rate for plastering shall include the cost of all labour, materials,
tools and plant, scaffolding and all incidental expenses, sampling and testing and
supervision as described in these specifications.
The contract unit rate for pointing shall include erecting and removal of
scaffolding, all labour, materials, and equipment incidental to complete the
pointing, raking out joints, cleaning, wetting, filling with mortar, trowelling, pointing
and watering, sampling and testing and supervision as described in these
specifications.
The contract unit rate for architectural coping shall include cost of all labour,
materials, tools and plant, sampling and testing and supervision as described in
these specifications.

1400 STONE MASONRY

1401 DESCRIPTION
This work shall consist of the construction of structures with stones jointed
together by cement mortar in accordance with the details shown on the drawings
and these specifications or as approved by the Engineer.
1402 MATERIALS
All materials used in stone masonry shall conform to Section 1000 expect cement
mortar for stone masonry which shall conform to Clause 1304.
1403 PERSONNEL
Only trained personnel shall be employed for construction and supervision.
1404 TYPE OF MASONRY
The type of masonry used for structures shall be random masonry (coursed or
uncoursed) or coursed rubble masonry (First sort). However, for bridge work
generally, course rubble stone masonry shall be used. The actual type of
masonry used for different parts of structures shall be specified on the drawings.
For facing work, ashlar masonry shall be used where indicated on the drawings.
1405 CONSTRUCTION OPERATIONS
1405.1 General Requirements
The dressing of stone shall be as specified for individual type masonry work and
it shall also conform to the general requirements of IS: 1597 and requirement for
dressing of stone covered in IS:1129. Other specific requirements are covered
separately with respect to particular types of rubble stone work.

1405.2 Laying
1405.2.1 The masonry work shall be laid to lines, levels, curves and shapes as shown in
the plan. The height in each course shall be kept same and every stone shall be
fine tooled on all beds joints and face full and true. The exposed faces shall be
gauged out, grooved, regulated and sunk or plain moulded as the case may be.
The faces of each stone between the draft be left rough as the stone comes from
quarry except where sacrificial layer is to be provided or plastering is resorted to
due to aggressive environment.
1405.2.2 Stones shall be sufficiently wetted before laying to prevent absorption of water
from mortar.
Stratified stones must be laid on their natural beds. All bed joints shall be normal
to the pressure upon them.
Stones in the hearting shall be laid on their broadest face that gives a better
opportunity to fill the spaces between stones.
The courses of the masonry shall ordinarily be pre-determined. They shall

generally be of the same height. When there is to be variation in the height of
courses, the larger courses are to be placed at lower levels, heights of courses
decreasing gradually towards the top of the wall. The practice of placing loose
mortar on the course and pouring water on it to fill the gaps in stones is not
acceptable. Mortar may be fluid mixed thoroughly and then poured in the joints.
No dry or hollow space shall be left anywhere in the masonry and each stone
shall have all the embedded faces completely covered with mortar.
In tapered walls, the beds of the stones and the planes of course should be at
right angles to the batter. In case of bridge piers with batter on both sides, the
course shall be horizontal.
The bed which is to receive the stone shall be cleaned, wetted and covered with
a layer of fresh mortar. All stones shall be laid full in mortar both in bed and
vertical joints and settled carefully in place with a wooden mallet immediately on
placement and solidly embedded in mortar before it has set. Clean chips and
spalls shall be wedged into the mortar joints and bed wherever necessary to
avoid thick beds or joints of mortar. When the foundation masonry is laid directly
on rock, the face stones of the first course shall be dressed to fit into rock snugly
when pressed down in the mortar bedding over the rock. No dry or hollow space
shall be left anywhere in the masonry and each stone shall have all the

embedded faces completely covered with mortar. For masonry works over rock, a
leveling course of 100 mm thickness and in concrete M 15 shall be laid over rock
and then stone masonry work shall be laid without foundation concrete block.
Face works and hearting shall be brought up evenly but the top of each course
shall not be levelled up by the use of flat chips.
For sharp corners specially in skew bridges, through stones shall be used in
order to avoid spalling of corners.
In case any stone already set in mortar is disturbed or the joints broken, it shall
be taken out without disturbing the adjoining stones and joints. Dry mortar and
stones thoroughly cleaned from the joints and stones and the stones reset in
fresh mortar. Attempt must never be made to slide one stone on top of another,
freshly laid.
Shaping and dressing shall be done before the stone is laid in the work. No
dressing and hammering, which will loosen the masonry, will be allowed after it is
once placed. All necessary chases for joggles, dowels and clamps should be
formed before hand.
Sufficient transverse bonds shall be provided by the use of bond stone extending
from the front to the back of the wall and in case of thick wall from outside to the
interior and vice versa. In the latter case, bond stones shall overlap each other in
their arrangement.
In case headers are not available, precast headers of M 15 concrete shall be

used. Cast-in-situ headers are not permitted.
Stones shall break joint on the face for at least half the height of the course and
the bond shall be carefully maintained throughout.
In band work at all angle junctions of walls, the stones at each alternate course
shall be carried into each of the respective walls so as to unite the work
thoroughly.
The practice of building up thin faces tied with occasional through stones and
filling up the middle with small stuff or even dry packing is not acceptable.
All quoins and the angles of the opening shall. be made from selected stones,
carefully squared and bedded and arranged to bond alternately long and short in
both directions.

All vertical joints shall be truly vertical. Vertical joints shall be staggered as far as
possible. Distance between the nearer vertical joints of upper layer and lower
shall not be less than half the height of the course.
Only rectangular shaped bond stones or headers shall be used. Bond stones
shall overlap each other by 150 mm or more.
All connected masonry in a structure shall be carried up nearly at one uniform

level throughout but when breaks are unavoidable the masonry shall be raked in
sufficiently long steps to facilitate jointing of old and new work. The stepping of
raking shall not be more than 45 degrees with the horizontal.
1405.3 Random Masonry (Uncoursed and Coursed)
1405.3.1 Dressing:
Stone shall be hammer dressed on the face, the sides and beds to enable it to
come in proximity with the neighbouring stone. The bushing on the exposed face
shall not be more than 40 mm.
1405.3.2 Insertion of chips:
Chips and spalls of stone may be used wherever necessary to avoid thick mortar
beds or joints and it shall be ensured that no hollow spaces are left anywhere in
the masonry. The chips shall not be used below hearting stones to bring these
upto the level of face stones. Use of chips shall be restricted to filling of
interstices between the adjacent stones in hearting and they shall not exceed 20
per cent of the quantity of stone masonry.
1405.3.3 Hearting stones:
The hearting or interior filling of the wall face shall consist of. rubble stones not
less than 150 mm in any direction, carefully laid, hammered down with a wooden
mallet into position and solidly bedded in mortar. The hearting should be laid
nearly level with facing and backing.
1405.3.4 Bond stones:
Through bond stones shall be provided in masonry upto 600 mm thickness and in
case of masonry above 600 mm thickness, a set of two or more bond stones
overlapping each other at least by 150 mm shall be provided in a line from face to
back. In case of highly absorbent types of stones (porous limestone and
sandstones, etc.,) the bond stone shall extend only about two-third into the wall,

as through stones in such cases may give rise to penetration of dampness and
therefore, for all thicknesses of such masonry, a set of two or more bond stones
overlapping each other by at least 150 mm shall be provided. One bond stone or
a set of bond stones shall be provided for every 0.50 sq. m. of the masonry
surface.
1405.3.5 Quoin stone:
Quoin stone i.e. stone specially selected and neatly dressed for forming an
external angle in masonry work, shall not be less than 0.03 cubic metre in
volume.
1405.3.6 Plum Stone:
The plum stones are selected long stones embedded vertically in the interior of
the masonry to form a bond between successive courses and shall be provided
at about 900 mm intervals.
1405.3.7 Laying:
The masonry shall be laid with or without courses as specified. The quoins shall
be laid header and stretcher alternately. Every stone shall be fitted to the
adjacent stone so as to form neat and close joint. Face stone shall extend and
bond well in the back. These shall be arranged to break joints, as much as
possible, and to avoid long vertical lines of joints.
1405.3.8 Joints:
The face joints shall not be more than 20 mm thick, but shall be sufficiently thick
to prevent stone-to-stone contact and shall be completely filled with mortar.
1405.4 Square Rubble - Coursed Rubble (First Sort)
1405.4.1 Dressing:
Face stones shall be hammer dressed on all beds and joints so as to give them
rectangular shape. These shall be square on all joints and beds. The bed joints
shall be chisel drafted for at least 80 mm back from the face and for at least 40
mm for the side joints. No portion of the dressed surface shall show a depth of
gap more than 6 mm from the straight edge placed on it. The remaining
unexposed portion of the stone shall not project beyond the surface of bed and
side joints. The requirements regarding bushing shall be the same as for random
rubble masonry.

1405.4.2 Hearting stones:
The hearting or interior filling of the wall face shall consist of flat bedded stone
carefully laid, on prepared beds in mortar. The use of chips shall be restricted to
the filling of interstices between the adjacent stones in hearting and these shall
not exceed 10 per cent of the quantity of masonry. While using chips it shall be
ensured that no hollow spaces are left anywhere in the masonry.
The requirements regarding through or bond stone shall be the same as for
random rubble masonry, but these, shall be provided at 1.5 metre to 1.8 metre
apart clear in every course
1405.4.4 Quoin stone:
The quoins shall be of the same height of the course in which these occur and
shall be formed of header stones not less than 450mm in length. They shall be
laid lengthwise alternately along each face, square in their beds which shall be
fairly dressed to a depth of at least 100 mm.
1405.4.5 Face stone:
Face stones shall tail into the work for not less than their heights and at least
one-third of the stones shall tail into the work for a length not less than twice their
height. These shall be laid as headers and stretchers alternately.
1405.4.6 laying:
The stones shall be laid on horizontal courses and all vertical joints should be
truly vertical. The quoin stones should be laid header and stretcher alternately
and shall be laid square on their beds, which shall be rough chisel dressed to a
depth of at least 100 mm.
1405.4.7 Joints:
The face joints shall not .be more than 10 mm thick, but shall be sufficiently thick
to prevent stone-to-stone contact and shall be completely filled with mortar.

1405.5 Ashlar Masonry (Plain Ashlar)
1405.5.1 Dressing:
Every stone shall be cut to the required size and shape, chisel dressed on all
beds and-joints so as to be free from all bushing. Dressed surface shall not show
a depth of gap of more than 3 mm from straight edge placed on it. The exposed
faces and joints, 6 mm from the face shall be fine tooled so that a straight edge
can be laid along the face of the stone in contact with every point. All visible
angles and edges shall be true and square and free from chip pings. The corner
stones (quoins) shall be dressed square and corner shall be straight and vertical.
Through bond stones shall be provided in masonry upto 600 mm thickness and in
case of masonry above 600 mm thickness, a set of two or more bond stones
overlapping each other at least by 150 mm shall be provided in a line from face to
back. In case of highly absorbent types of stones (porous limestone and
sandstones, etc.,) the bond stone shall extend only about two-third into the wall,
as through stones in such cases may give rise to penetration of dampness and,
therefore, for all thicknesses of such masonry a set of two or more bond stones
overlapping each other by at least 150 mm shall be provided. One bond stone or
a set of bond stones shall be 1.5 metres to 1.8 metres apart dear in every course.
1405.5.3 Laying:
The face stone shall be laid header and stretcher alternately, the header being
arranged to come as nearly as possible in the middle of stretchers above and
below. Stones shall be laid in regular courses not less than 300 mm in height and
all courses of the same height unless otherwise specified. No stone shall be less
in width than its height or less in length than twice its height, unless otherwise
specified.
1405.5.4 Joints:
All joints shall be full of mortar. These shall not be less than 3 mm thick. Face
joints shall be uniform throughout, and a uniform recess of 20 mm depth from
face shall be left with the help of a stone plate during the progress of work.

1405.6 Pointing
Pointing shall be carried out using mortar not leaner than 1:3 by volume of
cement and sand or as shown on the drawing. The mortar shall be filled and
pressed into the raked out joints before giving the required finish. The pointing
shall conform to Clause 1312.3 of the specification. The work shall conform to
IS:2212. The thickness of joints shall not be less than 3 mm for Ashlar masonry.
However, the maximum thickness of joints in different works shall be as follows:
Random Rubble: 20mm

Coursed Rubble: 15mm
Ashlar Masonry : 5mm
1405.7 Curing
Curing shall conform to Clauses 1309 and 1312.5
1405.8 Scaffolding
For scaffolding Clause 1310 shall apply.
1405.9 Weep Holes
Weep holes shall conform to Clause 2706.
1405.10 Jointing with Existing Structures
For Jointing with existing structures, the specifications given under Clause 1308
shall apply.
1406 ARCHITECTURAL COPING FOR WING/RETURN/ PARAPET WALLS
Architectural coping for wing/return/parapet walls shall conform to Clause 1313.
1407 TESTS AND STANDARD OF ACCEPTANCE
All work shall be done to the lines and levels as indicated on the drawing or as
directed by the Engineer subject to tolerances as specified in these
specifications.
Mortar cubes shall be taken in accordance with IS:2250 for compressive strength,
consistency of mortar and its water retentivity. The frequency of testing shall be
one sample for every two cubic metres of mortar subject to a minimum 3 samples
for a day's work.
Stone masonry shall be measured in cubic metres.

1500 FORM WORK

1501 DESCRIPTION
Formwork shall include all temporary or permanent forms required for forming the
concrete of the shape, dimensions and surface finish as shown on the drawing or
as directed by the Engineer, together with all props, staging, centering,
scaffolding and temporary construction required for their support. The design,
erection and removal of formwork shall conform to IRC:87 "Guidelines for Design
and Erection of Falsework for Road Bridges" and these specifications.
1502 MATERIALS
All materials shall comply with the requirements of IRC:87:2011. Materials and
components used for formwork shall be examined for damage or excessive
deterioration before use / re-use and shall be used only if found suitable after
necessary repairs. In case of timber formwork, the inspection shall not only cover
physical damages but also signs of attacks by decay, rot or insect attack or the
development of splits.
Forms shall· be constructed with metal or timber. Tire metal used for forms shall
be of such thickness that the forms remain true to shape. All bolts should be
countersunk. The use of approved internal steel ties or steel or plastic spacers
shall be permitted. Structural steel tubes used as support for forms shall have a
minimum wall thickness of 4 mm. Other materials conforming to the requirements
of IRC:87:2011may also be used if approved by the Engineer. (As per Clause
4.2 Table 4.1 of RC:87:2011)
TABLE 1500-1 SPECIFICATION FOR MATERIALS
Specification and
Material Principal use Minimum size design data Remarks
sources
1 2 3 4 5
Soft woods 01
partially seasoned
i) Form, shoring
a) Timber IS 883 stock are
and
recommended for
formwork since

Specification and
sources
1 2 3 4 5
fully dried timber

swells excessively
when it becomes
wet and green
timber will dry out
and warp during
hot weather.
ii) Form for deck

soffit, beam
25 mm -do-
sides and other
vertical surfaces
iii) Beam soffit

50mm 30mm -do-
columns side
iv) Props 75 x 100 mm -do-
v) Bailers for 75 mm Dia

shore / Bracing minimum
Plywood provides
large area of joint
free smooth
concrete surface,
easy in handling.
Forms and Form
light weight,
b)Ply-wood linings Sheeting 6 mm IS 4990
flexibility of use,
and panels
capacity to
withstand hot and
cold climates, no
shrinkage cupping
or twisting, high

Specification and
sources
1 2 3 4 5
resistance to
impact load and
vibration, as of
bonding,
reusability
Steel forms can

stand repetitive
Forms and Form IS 2062
use. Note: - Plate
linings 3.15 mm
c) Steel i) Steel Plate IS 961 thickness may be
with form
increased if
vibrators IS 1977
repetitive use is
500 or more
Form supports
shoring &
framing, (i) Steel framing and
Angles bracing can be
50x50x6mm (ii) used in
IS 961
Flats 50 x 6 mm conjunction with
IS 226 timber and
ii) Rolled (iii) Tubes 40
sections and mm dia nominal IS 1161 plywood panel
tubes bore with wall system.

IS 1977
thickness 4.05 Note: Sections
IS 2062
mm for main may be increased
members and up if repetitive use
25 mm dia for is 500 or more
secondary
members
iii) Proprietary Forms can be Design data to be

Systems obtained for obtained from the

Specification and
sources
1 2 3 4 5
round, square manufacturer of

rectangular or the proprietary
polygonal systems.
shapes
Formwork
components
such as plates,
prop, frames ,
accessories and
trestles, etc,
iv) Clamps/
Couplers for IS 2750
tubular centering
Light weight
panels and
d) Aluminium Manufacturer's
forming systems
Alloys data
shoring and
falsework
This material is a
glass fibre
Precast reinforced plastic
concrete product, excellent
Manufacturer's
e) Fibre Glass construction and cast-concrete
data
architectural surfaces can be
concrete moulded to any
shape without
joints or seems
f) Precast 37 mm

Specification and
sources
1 2 3 4 5
concrete
Usually left in
Column forms
g) Asbestos position and
and duct
cement provides the
formers
finished surtace
h) Laminated
Circular column
pressed paper, Manufacturer's
forms, formers
tubes (Card data
for small ducts
Board)
(i) Hard board Form panels Minimum 12 mm

·do·
with lining and G.I. lining thick
(j) Plastic
Polyeterene, Formliners for
Polyethylene decorative ·do·
Polyvinyl concrete
Chloride
Form lining and

k) Rubber ·do·
void forms
Codes:
IS 4990 Specification for Plywood for Concrete Shuttering work.
IS 226 Specification for Structural Steel (Standard Quality)
IS 2062 Specification for Structural Steel (Welding Quality)
IS 961 Specification for Structural Steel (High Quality) IS 1977 Specification for
Structural Steel (High Steel)
IS 1161 Specification for Tubes for Structural purposes.

Note: The sizes given in Table 15.1 are only indicative of the minimum
requirements and shall be derived from the actual detailed design.
1503 DESIGN OF FORMWORK
1503.1 The Contractor shall furnish the design and drawing of complete formwork (Le.
the forms as well as their supports) for approval of the Engineer before any
erection is taken up. If proprietary system of formwork is used, the Contractor
shall furnish detailed information as per Appendix 7500/7 to the Engineer for
approval.
Notwithstanding any approval or review of drawing and design by the Engineer,

the Contractor shall be entirely responsible for the adequacy and safety for form
work.
1503.2 The design of the formwork shall conform to provisions of IRC:87:2011. It shall
ensure that the forms can be conveniently / removed without disturbing the
concrete. The design shall facilitate proper and safe access to all parts of
formwork for inspection.
1503.3 In the case of prestressed concrete superstructure, careful consideration shall be

given to redistribution of loads on props due to prestressing.
1504 WORKMANSHIP
1504.1 The formwork shall be robust and strong and the joints shall be leak-proof.
Balli shall not be used as staging. Staging must have cross bracings and
diagonal bracings in both directions. Staging shall be provided with an
appropriately designed base plate resting on firm strata.
1504.2 The number of joints in the formwork shall be kept to a minimum by using large
size panels. The design shall provide for proper "soldiers" to facilitate alignment.
All joints shall be leak proof and must be properly sealed. Use of PVC JOINT
sealing tapes, foam rubber or PVC T-section is essential to prevent leakage of
grout.
1504.3 As far as practicable, clamps shall be used to hold the forms together. Where use
of nails is unavoidable minimum number of nails shall be used and these shall be
left projecting so that they can be withdrawn easily. Use of double headed nails
shall be preferred.
1504.4 Use of ties shall be restricted, as far as practicable. Wherever ties are used they
shall be used with HDPE sheathing so that the ties can easily be removed. No

parts prone to corrosion shall be left projecting or near the surface. The sheathing
shall be grouted with cement mortar of the same strength as that of the structure.
1504.5 Unless otherwise specified, or directed, chamfers or fillets of sizes 25 mm x 25

mm shall be provided at all angles of the formwork to avoid sharp corners. The
chamfers, bevelled edges and mouldings shall be made in the formwork itself.
Opening for fixtures and other fittings shall be provided in the shuttering as
directed by the Engineer.
1504.6 Shuttering for walls, sloping members and thin sections of considerable height
shall be provided with temporary openings to permit inspection and cleaning out
before placing of concrete.
1504.7 The formwork shall be constructed with pre-camber to the soffit to allow for
deflection of the formwork. Pre-camber to allow for deflection of form work shall
be in addition to that indicated for the permanent structure in the drawings.
1504.8 Where centering trusses or launching trusses are adopted for casting of
superstructure, the joints of the centering trusses, whether welded, riveted or
bolted should be thoroughly checked periodically. Also, various members of the
centering trusses should be periodically examined for proper alignment and
unintended deformation before proceeding with the concreting. They shall also be
periodically checked for any deterioration in quality due to steel corrosion.
1504.9 The formwork shall be so made as to produce a finished concrete true to shape,
line and levels and dimensions as shown on the drawings, subject to the
tolerances, specified in respective sections of these specifications, or as directed
by the Engineer.
1504.10 Where metal forms are used, all bolts and rivets shall be countersunk and well
ground to provide a smooth, plane surface. Where timber is used it shall be well
seasoned, free from loose knots, projecting nails, splits or other defects that may
mar the surface of concrete.
1504.11 Forms shall be made sufficiently rigid by the use of ties and bracings to prevent
any displacement or sagging between supports. They shall be strong enough to
withstand all pressure, ramming and vibration during and after placing the
concrete. Screw jacks or hard wood wedges where required shall be provided to
make up any settlement in the formwork either before or during the placing of
concrete.

1504.12 The formwork shall take due account of the calculated amount of positive or
negative camber so as to ensure the correct final shape of the structures, having
regard to the deformation of false work, scaffolding or propping and the
instantaneous or deferred deformation due to various causes affecting
prestressed structures.
1504.13 Suitable camber shall be provided to horizontal members of structure, specially in

long spans to counteract the effects of deflection. The form work shall be so fixed
as to provide for such camber.
1504.14 The formwork shall be coated with an. approved release agent that will effectively
prevent sticking and will not stain the concrete surface. lubricating (machine oils)
shall be prohibited for use as coating.
1505 FORMED SURFACE AND FINISH
The formwork shall be lined with material approved by the Engineer so as to

provide a smooth finish of uniform texture and appearance. This material shall
leave no stain on the concrete and so fixed to its backing as not to impart any
blemishes. It shall be of the same type and obtained from only one source
throughout for the construction of anyone structure. The contractor shall make
good any imperfections in the resulting finish as required by the Engineer.
Internal ties and -embedded metal parts shall be carefully detailed and their use
shall be subject to the approval of the Engineer.
1506 PRECAUTIONS
(i) Special measures in the design of formwork shall be taken to ensure that it
does not hinder the shrinkage of concrete. The soffit of the formwork shall be so
designed as to ensure that the formwork does not restrain the shortening and/or
hogging of beams during prestressing. The forms may be removed at the earliest
opportunity subject to the minimum time for removal of forms with props retained
in position.
(ii) Where necessary, formwork shall be so arranged that the soffit form, properly
supported on props only can be retained in position for such period as may be
required by maturing conditions. ...
(iii) Any cut-outs or openings provided in any structural member to facilitate

erection of formwork shall be dosed with the same grade of concrete as the
adjoining structure immediately after removal of formwork ensuring watertight
joints.

(iv) Provision shall be made for safe access on, to and about the formwork at the
levels as required.
(v) Close watch shall be maintained to check for settlement of formwork during
concreting. Any settlement of formwork during concreting shall be promptly
rectified.
(vi) Water used for curing should not be allowed to stagnate near the base plates
supporting the staging and should be properly drained.
(vii) Photographic record of formwork shall be maintained.
1507 PREPARATION OF FORMWORK BEFORE CONCRETING
The inside surfaces of forms shall, except in the case of permanent form work or
where otherwise agreed to by the Engineer be coated with a release agent
supplied by approved manufacturer or of an approved material to prevent
adhesion of concrete to the formwork. Release agents shall be applied strictly in
accordance with the manufacturer's instructions and shall not be allowed to come
into contact with any reinforcement or prestressing tendons and anchorages.
Different release agents shall not be used in formwork for exposed concrete.
Before re-use of forms, the following actions shall be taken:
(i) The contact surfaces of the forms shall be cleaned carefully and dried before
applying a release agent
(ii) It should be ensured that the release agent is appropriate to the surface to be
coated. The same type and make of release agent shall be used throughout on
similar formwork materials and different types should not be mixed.
(iii) The form surfaces shall be evenly and thinly coated with release agent. The
vertical surface shall be treated before horizontal surface and any excess wiped
out.
(iv) The release agent shall not come in contact with reinforcement or the
hardened concrete.
All forms shall be thoroughly cleaned immediately before concreting. The

Contractor shall give the Engineer due notice before placing any concrete in the
forms to permit him to inspect and approve the form work, but such inspection
shall not relieve the contractor of his responsibility for safety of formwork, men,
machinery, materials and finish or tolerances of concrete. Formwork of all major
spans shall be checked by Dy.Ch.Eng (Bridges) and certified before con creating.

1508 REMOVAL OF FORMWORK
The scheme for removal of formwork (i.e. de-shuttering and de-shuttering) shall
be planned in advance and· furnished to the Engineer for scrutiny and approval.
No formwork or any part thereof shall be removed without prior approval of the
Engineer.
The formwork shall be so removed as not to cause any damage to concrete.

Centering shall be gradually and uniformly lowered in such a manner as to permit
the concrete to take stresses due to its own weight uniformly and gradually to
avoid any shock or vibration.
Where not specifically approved, the time of removal of form work (when ordinary
Portland Cement is used without any admixtures at an ambient temperatures
exceeding 10 degrees Celsius) shall be as under:
a) Walls, piers, abutments, 12 to 48 hours as may be
columns and vertical faces decided by the Engineer
of structural members
b) Soffits of Slabs (with props left under): 3 days
c) Props (left under slabs): 14 days
d) Soffit of Girders (with props left under): 7 days
e) Props (left under girders): 21 days
Where there are re-entrant/angles in the concrete sections, the formwork should
be removed at these sections as soon as possible after the concrete has set, in
order to avoid cracking due to shrinkage of concrete.
1509 RE-USE OF FORMWORK
When formwork is dismantled, its individual components shall be examined for

damage and damaged pieces shall be removed for rectification. Such
examination shall always be carried out before being used again. Before re-use
all components shall be cleaned of deposits of soil, concrete or other unwanted
materials. Threaded parts shall be oiled after cleaning. All bent steel props shall
be straightened before re-use. The maximum deviation from straightness is 1/600
of the length. The maximum permissible axial loads in used props shall be
suitably reduced depending upon their condition. The condition of the timber
components, plywood and steel shuttering plates shall be examined closely for
distortion and defects before re-use.

1510 SPECIALIED FORMWORK
Specialized formwork may be required in the case of slipform work, underwater

concreting, segmental construction etc. Such specialised formwork shall be
designed and detailed by competent agencies and a set of complete working
drawings and installation instruction shall be supplied to the Engineer. The site
personnel shall be trained in the erection and dismantling as well as operation of
such specialised formwork. In case proprietary equipment is used, the supplier
shall supply drawings, details, installation instructions in the form of manual along
with the formwork. Where specialised formwork is used, close co-ordination with
the design of permanent structure is necessary.
For slipform the rate of slipping the formwork shall be designed for each
individual case taking into account various parameters including the grade of
concrete, concrete strength, concrete temperature, ambient temperature,
concrete admixtures, etc. In the case of segmental construction, the concrete mix
shall be normally designed for developing high early strength so that the form
work is released as early as possible. In order to verify the time and sequence of
striking/removal of specialized formwork routine field tests for the consistency of
concrete and strength development are mandatory and shall be carried out
before adoption.
For specialised formwork, the form lining material may be either plywood or steel
sheet of appropriate thickness. Plywood is preferred where superior quality of
surface is desired, whereas steel sheeting is normally used where large number
of repetitions are involved.
1511 TEST AND STANDARDS OF ACCEPTANCE
The material shall be tested in accordance with these Specifications and shall
1512 MEASUREMENT FOR PAYMENT
Unless stated otherwise the rate for concrete in Plain Concrete or Reinforced
Concrete or Prestressed Concrete shall be deemed to include all form work

required in accordance with this section and shall not be measured separately.

Where it is specifically stipulated in the Contract that the formwork shall be paid
for separately, measurement of form work shall be taken in square meters of the
surface area of concrete which is in contact with form work.
1513 RATE
The unit rate of the Plain Concrete or Reinforced Concrete or Prestressed

Concrete as defined in respective sections shall be deemed to cover the costs of
all formwork, including cost of all materials, labour, tools and plant required for
design, construction and removal of formwork and supervision as described in
this section including properly supporting the members until the concrete is
cured, set and hardened as required.
Where the contract unit for formwork is specifically provided as a separate item it
shall include the cost of all materials, labour, tools and plant required for design,
construction and removal of formwork and supervision as described in this
Section including properly supporting the members until the concrete is cured, set
and hardened as required.

1600 STEEL REINFORCEMENT (UNTENSIONED)

1601 DESCRIPTION
This work shall consist of furnishing and placing coated or uncoated mild steel or
high strength deformed reinforcement bars (untensioned) of the shape and
dimensions shown on the drawings and conforming to these Specifications or as
1602 GENERAL
Steel for reinforcement shall meet with the requirements of Section 1000.
Reinforcements may be either mild steel/medium tensile steel or high strength

deformed bars. They may be uncoated or coated with epoxy or with approved
protective coatings.
1603 PROTECTION OF REINFORCEMENT
Uncoated reinforcing steel shall be protected from rusting or chloride

contamination. Reinforcements shall be free from rust, mortar, loose mill scale,
grease, oil or paints. This may be ensured either by using reinforcement fresh
from the factory or thoroughly cleaning all reinforcement to remove rust using any
suitable method such as sand blasting, mechanical wire brushing, etc., as
directed by the Engineer. Reinforcements shall be stored on blocks, racks or
platforms and above the ground in a clean and dry condition and shall be suitably
marked to facilitate inspection and identification.
Portions of uncoated reinforcing steel and dowels projecting from concrete, shall
be protected within one week after initial placing of concrete with a brush coat of
neat cement mixed with water to a consistency of thick paint. This coating shall
be removed by lightly tapping with a hammer or other tool not more than one
week before placing of the adjacent pour of concrete. Coated reinforcing steel
shall be protected against damage to the coating. If the coating on the bars is
damaged during transportation or handling and cannot be repaired, the same
shall be rejected.
1604 BENDING OF REINFORCEMENT
Bar bending schedule .shall be furnished by the Contractor and got approved by
the Engineer before start of work.
Reinforcing steel shall conform to the dimensions and shapes given in the
approved Bar Bending Schedules.

Bars shall be bent cold to the specified shape and dimensions or as directed by
the Engineer using a proper bar bender, operated by hand or power to obtain the
correct radii of bends and shape.
Bars shall not be bent or straightened in a manner that will damage the parent
material or the coating.
Bars bent during transport or handling shall be straightened before being used on
work and shall not be heated to facilitate straightening.
1605 PLACING OF REINFORCEMENT
a) The reinforcement cage should generally be fabricated in the yard at ground

level and then shifted and placed in position. The reinforcement shall be placed
strictly in accordance with the drawings and shall be assembled in position only
when the structure is otherwise ready for placing of concrete. Prolonged time gap
between assembling of reinforcements and casting of concrete, which may result
in rust formation on the surface, shall not be permitted.
b) Reinforcement bars shall be placed accurately in position as shown on the

drawings. The bars, crossing one another shall be tied together at every
intersection with binding wire (annealed), conforming to IS:280 to make the
skeleton of the reinforcement rigid such that the reinforcement does not get
displaced during placing of concrete, or any other operation. The diameter of
binding wire shall not be less than 1 mm.
c) Bars shall be kept in position usually by the following methods:
(i) In case of beam and slab construction, industrially produced polymer cover
blocks of thickness equal to the specified cover shall be placed between the bars
and formwork subject to satisfactory evidence that the polymer composition is not
harmful to concrete and reinforcement. Cover blocks made of concrete may be
permitted by the Engineer, provided they have the same strength and
specification as those of the member.
(ii) In case of dowels for columns and wails, the vertical reinforcement shall be
kept in position by means of timber templates with slots cut in them accurately, or
with cover blocks tied to the reinforcement Timber templates shall be removed
after the concreting has progressed upto a level just below their location.
(iii) layers of reinforcements shall be separated by spacer bars at approximately

one metre intervals. The minimum diameter of spacer bars shall be 12 mm or
equal to maximum size of main reinforcement or maximum size of coarse

aggregate, whichever is greater. Horizontal reinforcement shall not be allowed to

sag between supports.
(iv) Necessary stays, blocks, metal chairs, spacers, metal hangers, supporting
wires etc, or other subsidiary reinforcement shall be provided to fix the
reinforcements firmly in its correct position.
(v) Use of pebbles, broken stone, metal pipe, brick, mortar or wooden blocks etc.,
as devices for positioning reinforcement shall not be permitted.
d) Bars coated with epoxy or any other approved protective coating shall be
placed on supports that do not damage the coating. Supports shall be installed in
a manner such that planes of weakness are not created in hardened concrete.
The coated reinforcing steel shall be held in place by use of plastic or plastic
coated binding wires especially manufactured for the purpose. Reference shall be
made to Section 1000 for other requirements.
e) Placing and fixing of reinforcement shall be inspected and approved by the

Engineer before concrete is deposited.
f) Reinforcement should be handled with rubber gloves and rubber coated pair of
toungs and padded equipment and with rubber shoes.
g) frequent monitoring of scaling off of coating and redoing of same till concreting
shall be done.
1606 BAR SPLICES
1606.1 Lapping
All reinforcement shall be furnished in full lengths as indicated on drawing. No

splicing of bars, except where shown on the drawing, will be permitted without
approval of the Engineer. The lengths of the splice shall be as indicated on
drawing or as approved by the Engineer. Where practicable, overlapping bars
shall not touch each other, and shall be kept apart by 25 mm or 1 1/4 times the
maximum size of coarse aggregate, whichever is greater. Lf this is not feasible,
overlapping bars shall be bound with annealed steel binding wire, not less than 1
mm diameter and twisted tight in such a manner as to maintain minimum clear
cover to the reinforcement from the concrete surface. lapped splices shall be
staggered or located at points, along the span where stresses are low

1606.2 Welding
1606.2.1 Splicing by welding of reinforcement will be permitted only if detailed on the

drawing or approved by the Engineer. Weld shall develop an ultimate strength
equal to or greater than that of the bars connected.
1606.2.2 While welding may be permitted for mild steel reinforcing bars conforming to
IS:432, welding of deformed bars conforming to IS:1786 shall in general be
prohibited. Welding may be permitted in case of bars of other than 5 240 grade
including special welding grade of S 415 grade bars conforming to IS:1786, for
which necessary chemical analysis has been assured and the carbon equivalent
(CE) calculated from the chemical composition using the formula:
is 0.4 or less.
1606.2.3 The method of welding shall conform to IS:2751 and IS:9417 and to any
supplemental specifications to the satisfaction of the Engineer. Welding may be
carried out by metal arc welding process. Oxyacetylene welding shall not be
permissible. Any other process may be used subject to' the approval of the
Engineer and necessary additional requirements to ensure satisfactory joint
performance. Precautions on over heating, choice of electrode, selection of
correct current in arc welding etc., should be strictly observed.
All bars shall be butt welded except for smaller diameter bars (diameter of less
than 20 mm) which may be lap welded. Single-V or Double-V butt joints may
generally be used. For vertical bars single bevel or double bevel joints may be
used.
Welded joints shall be located well away from bends and not less than twice the
bar diameter away from a bend.
Generally, shop welding in controlled conditions is to be preferred, where

feasible. Site welding where necessary shall, however, be permitted when the
facilities, equipment, process, consumables, operators, welding procedure are
adequate to produce and maintain uniform quality at par with that attainable in
shop welding to the satisfaction of the Engineer. Joint welding procedures which
are to be employed shall invariably be established by a procedure specification.
All welders and welding operators to be employed shall have to. be ,qualified by

tests prescribed in IS:2751. Inspection of welds shall conform to IS:822 and

destructive or nondestructive testing may be undertaken when deemed
necessary. Joints with weld defects detected by visual inspection or dimensional
check inspection shall not be accepted.
Suitable means shall be provided for holding the bars securely in position during
welding. It must be ensured that no voids are left in welding. When welding is
done in 2 or 3 stages, previous surface shall be cleaned properly. Bars shall be
cleaned of all loose scale, rust, grease, paint and other foreign matter before
carrying out welding. Only competent and experienced welders shall be
employed on the work with the approval of the Engineer. No welding shall be
done on coated bars.
M.S. electrodes used for welding shall conform to IS:814.
1606.2.4 Welded joints shall preferably be located at points where steel will not be subject
to more than 75 per cent of the maximum permissible stresses and welds so
staggered that at anyone section, not more than 20 per cent of the bars are
welded.
1606.2.5 Welded pieces of reinforcement shall be tested. Specimens shall be taken from
the site and the number and frequency of tests shall be as directed by the
Engineer.
1606.3 Mechanical Coupling of Bars
Bars may be joined with approved patented mechanical devices as indicated on

the drawing or as approved by the Engineer e.g. by special grade steel sleeves
swagged on to bars in end to end contact or by screwed couplers. In case such
devices are permitted by the Engineer, they shall develop at least 125 per cent of
the characteristic strength of the reinforcement bar.
1607 TESTING AND ACCEPTANCE
The material shall be tested in accordance with relevant IS specifications and

necessary test certificates shall be furnished. Additional tests, if required, will be
got carried out by the Contractor at his own cost.
The fabrication, furnishing and placing of reinforcement shall be in accordance

with these specifications and shall be checked and accepted by the Engineer.

Reinforcement shall be measured in length including hooks, if any, separately for

different diameters as actually used in work, excluding overlaps. From the length
so measured, the weight of reinforcement shall be calculated in tonnes on the
basis of IS: 1732. Wastage, overlaps, couplings, welded joints, spacer bars,
chairs, stays, hangers and annealed steel wire or other methods for binding and
placing shall not be measured and cost of these items shall be deemed to be
included in the rates for reinforcement
1609 RATE
The contract unit rate for coated/uncoated reinforcement shall cover the cost of
material, fabricating, transporting, storing, bending, placing, binding and fixing in
position as shown on the drawings as per these specifications and as directed by
the Engineer, including all labour, equipment, supplies, incidentals, sampling,
testing and supervision.
The unit rate for coated reinforcement shall be deemed to also, include cost of all
material, labour, tools and plant, royalty, transportation and expertise required to
carry out the work. The rate shall also cover sampling, testing and supervision
required for the work.

1700 STRUCTURAL CONCRETE

1701 DESCRIPTION
The work shall consist of furnishing and placing structural concrete and incidental
construction in accordance with these specifications and in conformity with the
lines, grades and dimensions, as shown on the drawings or as directed by the
Engineer.
1702 MATERIALS
All materials shall conform to Section 1000 of these Specifications.
1703 GRADES OF CONCRETE
1703.1 The grades of concrete shall be designated by the characteristic strength as

given in Table 1700-1, where the characteristic strength is defined as the strength
of concrete below which not more than 5 per cent of the test results are expected
to fall.
TABLE 1700-1 •CHARACTERISTIC STRENGTH OF CONCRETE
Specified characteristic Compressive strength

Grade Designation
of 150 mm cubes at 28 days, in MPa
M15 15
M20 20
M25 25
M30 30
M35 35
M40 40
M45 45
M50 50
M55 55
1703.2 The lowest grades of concrete in bridges and corresponding minimum cement
contents and water-cement ratios shall be maintained as indicated in Tables
1700-2 and 1700-3.
TABLE 1700-2 FOR BRIDGES WITH PRESTRESSED CONCRETE OR THOSE

WITH INDIVIDUAL SPAN LENGTHS MORE THAN 30 M OR THOSE THAT ARE
BUILT WITH INNOVATIVE DESIGN/CONSTRUCTION
(A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO

Max water cement ratio

Min. cement content
Structural
forall exposure Exposure Conditions
Member
conditions (kg/cu.m)
Normal Severe
a) PCCmembers 360 0.45 0.45
b) RCC
400 0.45 0.40
members
c) PSC
400 0.40 0.40
members
(B) MINIMUM STRENGTH OF CONCRETE
Conditions of Exposure
Member
Moderate Severe
a) PCCmembers M25 M30

b) RCC members M35 M40
c) PSC members M35 M40
TABLE 1700-3. FOR BRIDGES OTHER THAN THOSE MENTIONED IN TABLE
1700-2 AND FOR CULVERTS AND OTHER INCIDENTAL CONSTRUCTION
(A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO
Min. cement content Max. water cement

ratio
(kg/cu.m)
Member
Exposure Conditions Exposure Conditions
Normal Severe Normal Severe
a) PCCmembers 250 310 0.50 0.45
b) RCC 0.45 0.40
310 400
members
(B) MINIMUM STRENGTH Of CONCRETE
Conditions of Exposure
Member
Moderate Severe
a) PCCmembers M15 M20

b) RCC members M20 M25
Notes Applicable to Tables 1700-2 and 1700-3

(i) The minimum cement content is based on 20 mm aggregate (nominal max.

size). For 40 mm and larger size aggregates,- it may be reduced suitably but the
reduction shall not be more than 10 per cent
(ii) For underwater concreting, the cement content shall be increased by 10 per
cent.
(iii) Severe conditions of exposure shall mean alternate wetting and drying due to
sea spray, alternate wetting and drying combined with freezing and buried in soil
having corrosive effect.
(iv) Moderate conditions of exposure shall mean other that those mentioned in
(iii) above.
The cement content shall be as low as possible but not less than the quantities
specified above. In no case shall it exceed 540 kg/cu.rru of concrete.
1703.3 Concrete used in any component or structure shall be specified by designation

along with prescribed method of design of mix i.e. "Design Mix" or "Nominal Mix".
For all items of concrete, only "Design Mix" shall be used, except where "Nominal
Mix" concrete is permitted as per drawing or by the Engineer. "Nominal Mix" may
be permitted only for minor bridges and culverts or other incidental construction
where strength requirements are upto M 20 only. "Nominal Mix" may also be
permitted for non-structural concrete or for screed below open foundations.
1703.4 If the Contractor so elects~ the Engineer may permit the use of higher grade
concrete than that specified on the drawing, 1n which event the higher grade
concrete shall meet the specifications applicable thereto without additional
compensation.
1704 PROPORTIONING OF CONCETRE
Prior to the start of construction, the Contractor shall design the mix in case of
"Design Mix Concrete" or propose nominal mix in case of "Nominal Mix
Concrete", and submit to the Engineer for approval, the proportions of materials,
including admixtures to be used. Water-reducing admixtures (including
plasticisers or super-plasticisers) may be used at the Contractor's option, subject
to the approval of the Engineer. Other types of admixtures shall be prohibited,
unless specifically permitted by the Engineer.

1704.1 Requirements of Consistency
The mix shall have the consistency which will allow proper placement and
consolidation in the required position. Every attempt shall be made to obtain
uniform consistency.
The optimum consistency for various types of structures shall be as indicated in

Table 1700-4, or as directed by the Engineer. The slump of concrete shall be
checked as per IS:516.
TABLE 1700-4.
TYPE
1. (a) Structures with exposed belined surface requiring 25
low slump concrete to allow proper compaction
(b) plain cement concrete 25
2. RCC structures with widely spaced reinforcements; 40 - 50
e.g. solid columns, piers, abutments, footings, weI! steining
3. RCC structures with fair degree of congestion of 50 - 75
reinforcement; e.g. pier and abutment caps,
box culverts well curb, well cap, walls with thickness
greater than 300 mm
4. RCC and PSC structures with highly congested 75 -125
reinforcements e.g. deck slab girders, box girders,
walls with thickness less than 300 mm
5. Underwater concreting through tremie 100-200
e.g. bottom plug, cast-in-situ piling
1704.2 Requirements for Designed Mixes
1704.2.1 Target mean strength
The target mean strength of specimen shall exceed the specified characteristic
compressive strength by at least the "current margin".
(i) The current margin for a concrete mix shall be determined by the Contractor
and shall be taken as 1.64 times the standard deviation of sample test results

taken from at least 40 separate batches of concrete of nominally similar

proportions produced at site by the same plant under similar supervision, over a
period exceeding 5 days, but not exceeding 6 months.
(ii) Where there is insufficient data to satisfy the above, the current margin for the
initial design mix shall be taken as given in Table 1700-5:
TABLE 1700-5.
Target Mean Strength

Concrete Grade Current Margin (MPa)
(MPa)
M15 10 2S
M20 10 30
M25 11 36
M30 12 42
M35 12 47
M40 12 52
M45 13 58
M50 13 63
M55 14 69
The initial current margin given in the Table 1700-5 shall be used till sufficient
data is available to determine the current margin as per sub-clause (i) above.
1704.2.2 Trial mixes
The Contractor shall give notice to enable the Engineer to be present at the
making of trial mixes and preliminary testing of the cubes. The Contractor shall
prepare trial mixes, using samples of approved materials typical of those he
proposes to use in the works, for all grades to the Engineer's satisfaction prior to
commencement of concreting. The initial trial mixes shall generally be carried out
in an established laboratory approved by the Engineer. In exceptional cases, the
Engineer may permit the initial trial mixes to be prepared at the site laboratory of
the Contractor, if a full fledged concrete laboratory has been established well
before the start of construction, to his entire satisfaction. In all cases complete
testing of materials forming the constituents of proposed, Design Mix shall have
been carried out prior to making trial mixes.
Sampling and testing procedures shall be in accordance with these

specifications.

When the site laboratory is utilised for preparing initial mix design, the concreting
plant and means of transport employed to make the trial mixes shall be similar to
that proposed to be used in the works.
Test cubes shall be taken from trial mixes as follows. For each mix, set of six
cubes shall be made from each of three consecutive batches. Three cubes from
each set of six shall be tested at an age of 28 days and three at an earlier age
approved by the Engineer. The cubes shall be made, cured, stored, transported
and tested in accordance with these specifications. The average strength of the
nine cubes at 28 days shall exceed the, specified characteristic strength by the
current margin minus 3.5 MPa.
1704.2.3 Control of strength of design mixes
a) Adjustment to Mix Proportion
Adjustments to mix proportions arrived at in the trial mixes shall be made subject
to the Engineer's approval, in order to minimise the variability of strength and to
maintain the target mean strength. Such adjustments shall not be taken to imply
any change in the current margin.
b) Change of Current Margin
When required by the Engineer, the Contractor shall recalculate the current
margin in accordance with Clause 1704.2.1. The recalculated value shall be
adopted as directed by the Engineer, .and it shall become the current margin for
concrete produced subsequently.
c) Additional Trial Mixes
During production, the Contractor shall carry out trial mixes and tests, if required
by the Engineer, before substantial changes are made in the material or in the
proportions of the materials to be used, except when adjustments to the mix
proportions are carried out in accordance with sub-clause (a) above.
1704.3 Requirements of Nominal Mix Concrete
Requirements for nominal mix concrete unless otherwise specified, shall be as

detailed in Table 1700-6.

TABLE 1700-6. PROPORTIONS FOR NOMINAL MIX CONCRETE
Total Quantity of dry aggregate by

Proportion of fine to
Concrete mass per 50 kg of cement to be taken
Coarse aggregate (by
Grade as the sum of individual masses of fine
mass)
and coarse aggregates (kg)
Generally 1:2, subject
M 15 350 to upper limit 1:1.5 and
lower limit of 1:2.5
M20 250 - do
1704.4 Additional Requirements
Concrete shall meet with any other requirements as specified on the drawing or
as directed by the Engineer. Additional requirements shall also consist of the
following overall limits of deleterious substances in concrete:
a) The total chloride content of all constituents of concrete as a percentage of

mass of cement in mix shall be limited to values given below:
prestressed Concrete 0.1 per cent
Reinforced concrete exposed to chlorides in service 0.2 per cent
(e.g. structures located near sea coast)
Other reinforced concrete construction 0.3 per cent
b) The total sulphuric anhydride (503) content of all the constituents of concrete
as a percentage of mass of cement in the mix shall be limited to 4 per cent
1704.5 Suitability of Proposed Mix Proportions
The Contractor shall submit the following information for the Engineer's approval:
a) Nature and source of each material
b) Quantities of each material per cubic metre of fully compacted concrete
c) Either of the following:
(i) appropriate existing data as evidence of satisfactory previous performance for

the target mean strength, current margin, consistency and water/cement ratio and
.any other additional requirement(s) as specified.
(ii) full details of tests on trial mixes.
d) Statement giving the proposed mix proportions for nominal mix concrete.

Any change in the source of material or in the mix proportions shall be subject to
the Engineer's prior approval.
1705 ADMIXTURES
Use of admixtures such as super plasticizers for concrete may be made with the
approval of the Engineer.
As the selection of an appropriate concrete admixture is an integral part of the

mix design, the manufacturers shall recommend the use of anyone of his
products only after obtaining complete knowledge of all the actual constituents of
concrete as well as methodologies of manufacture, transportation and
compaction of concrete proposed to be used in the project.
1706 SIZE OF COARSE AGGREGATE
The size (maximum nominal) of coarse aggregates for concrete to be used in

various components shall be given as Table 1700-7.
TABLE 1700-7.
Maximum Nominal Size of

Components
Coarse Aggregate (mm)
i) RCC well curb 20
ii) RCC/PCC well steining 40
iii) Well cap or Pile Cap Solid type
40
piers and abutments
iv) RCC work in girders, slabs,
wearing coat, kerb, approach
20
slab,hollow piers and
abutments,pier/abutment caps, piles
v) PSCwork 20
vi) Any other item As specified by the Engineer
Maximum nominal size of aggregates shall also be restricted to the smaller of the
following values:
a) 10 mm less than the minimum lateral dear distance between main

reinforcements
b) 10 mm less than the minimum dear cover to the reinforcements The

proportions of the various individual size of aggregates shall be so adjusted that
the grading produces densest mix and the grading curve corresponds to the
maximum nominal size adopted for the concrete mix.

1707 EQUIPMENT
Unless specified otherwise, equipment for production, transportation and

compaction of concrete shall be as under:
a) For Production of Concrete:
i) For overall bridge length of less than 200 metres - batch type concrete mixer
diesel or electric operated, with a minimum size of 200 litres, automatic water
measuring system and integral weigher (hydraulic/pneumatic type)
ii) For overall bridge length of 200 metres or more - concrete batching and mixing
plant fully automatic with minimum capacity of 15 cum.per hour.
All measuring devices of the equipment shall be maintained in a dean and

serviceable condition. Its accuracy shall be checked over the range in use, when
set up at each site and thereafter periodically as directed by the Engineer.
The accuracy of the measuring devices shall fall within the following limits:
Measurement of Cement ± 3 percent of the quantity of cement in each batch
Measurement of Water ± 3 percent of the quantity of water in each batch
Measurement of Aggregate ± 3 percent of the quantity of aggregate in each

batch
Measurement of Admixture ± 5 per cent of the quantity of admixture in each

batch
b) For concrete Transportation : Depending upon actual

requirement
i) Concrete dumpers minimum 2 tones capacity
ii) Powered hoist minimum 0.5 tone capacity
iii) Chutes
iv) bucket handled by cranes
v) transit truck mixer
vi) Concrete pump
v) Concrete distributer booms
vi) Belt conveyor

vii) Cranes with skips
viii) Tremies
c) For Compaction of Concrete:
i) Internal vibrators size 25 mm to 70 mm
ii) Form vibrators minimum 500 watts
iii) Screed vibrators (upto two lanes) full width of carriageway
1708 MIXING CONCRETE
Concrete shall be mixed either in a concrete mixer or in a batching and mixing

plant, as per these specifications. Hand mixing shall not be permitted. The mixer
or the plant shall be at an approved location considering the properties of the
mixes and the transportation arrangements available with the Contractor. The
mixer or the plant shall be approved by the Engineer.
Mixing shall be continued till materials are uniformly distributed and a uniform
colour of the entire mass is obtained, and each individual particle of the coarse
aggregate shows complete coating of mortar containing its proportionate amount
of cement. In no case shall mixing be done for less than 2 minutes.
Mixers which have been out of use for more than 30 minutes shall be thoroughly
cleaned before putting in a new batch. Unless otherwise agreed to by the
Engineer, the first batch of concrete from the mixer shall contain only two thirds of
the normal quantity of coarse aggregate. Mixing plant shall be thoroughly cleaned
before changing from one type of cement to another.
1709 TRANSPORTING, PLACING AND COMPACTION OF CONCRETE
The method of transporting and placing concrete shall be approved by the

Engineer. Concrete shall be transported and placed as near as practicable to its
final position, so that no contamination, segregation or loss of its constituent
materials takes place. Concrete shall not be freely dropped into place from a
height exceeding 1.5 metres.
When concrete is conveyed by chute, the plant shall be of such size and design
as to ensure practically continuous flow. Slope of the chute shall be so adjusted
that the concrete flows without the use of excessive quantity of water and without
any segregation of its ingredients. The delivery end of the chute shall be as dose
as possible to the point of deposit. The chute shall be thoroughly flushed with

water before and after each working period and the water used for this purpose
shall be discharged outside the formwork.
All formwork and reinforcement contained in it shall be cleaned and made free
from standing water, dust, snow or ice immediately before placing of concrete.
No concrete shall be placed in any part of the structure until the approval of the
Engineer has been obtained.
If concreting is not started within 24 hours of the approval being given, it shall
have to be obtained again from the Engineer. Concreting then shall proceed
continuously over the area between the construction joints. Fresh concrete shall
not be placed against concrete which has been in position for more than 30
minutes unless a proper construction joint is formed.
Except where otherwise agreed to by the Engineer, concrete shall be deposited

in horizontal layers to a compacted depth of not more than 450 mm when internal
vibrators are used and not exceeding 300 mm in all other cases.
Concrete when deposited shall have a temperature of not less than 5 degree
celsius, and not mere than 40 degrees Celsius. It shall be compacted in its final
position within 30 minutes of its discharge from the mixer, unless carried in
properly designed agitators, operating continuously, when this time shall be
within 1 hour of the addition of cement to the mix and within 30 minutes of its
discharge from the agitator. It may be necessary to add retarding admixtures to
concrete if trials show that the periods indicated above are unacceptable. In all
such matters, the Engineer's decision shall be final.
Concrete shall be thoroughly compacted by vibration or other means during

placing and worked around the reinforcement, tendons or duct formers,
embedded fixtures and into corners of the formwork to produce a dense
homogeneous void-free mass having the required surface finish. When vibrators
are used, vibration shall be done continuously during the placing of each batch of
concrete until the expulsion of air has practically ceased and in a manner that
does not promote segregation. Over vibration shall be avoided to minimise the
risk of forming a weak surface layer. When external vibrators are used, the
design of formwork and disposition of vibrator shall be such as to ensure efficient
compaction and to avoid surface blemishes. Vibrations shall not be applied
through reinforcement and where vibrators of immersion type are used, contact
with reinforcement and all inserts like ducts etc., shall be avoided. The internal
vibrators shall be inserted in an orderly manner and the distance between

insertions should be about one and a half times the radius of the area visibly
affected by vibration. Additional vibrators in serviceable condition shall be kept at
site so that they can be used in the event of breakdowns.
Mechanical vibrators used shall comply with IS:2502, IS:2506, IS:2514
and IS:4656 and shall have rubber coated needles.
1710 CONSTRUCTION JOINTS
Construction joints shall be avoided as far as possible and in no case the

locations of such joints shall be changed or increased from those shown on the
drawings, except with express approval of the Engineer. The joints shall be
provided in a direction perpendicular to the member axis. location, preparation of
surface and concreting of construction joints shall conform to the additional
specifications given in Appendix 170011.
1711 CONCRETING UNDER WATER
When it is necessary to deposit concrete under water, the methods, equipment,

materials and proportions of mix to be used shall be got approved from the
Engineer before any work is started. Concrete shall contain 10 per cent more
cement than that required for the same mix placed in the dry.
Concrete shall not be placed in water having a temperature below 5 . degrees

Celsius. The temperature of the concrete, when deposited, shall not be less than
16 degrees Celsius, nor more than 40 degrees Celsius. Coffer dams or forms
shall be sufficiently tight to ensure still water conditions, if practicable, and in any
case to reduce the flow of water to less than 3 metres per minute through the
space into which concrete is to be deposited. Coffer dams or forms in still water
shall be sufficiently tight to prevent loss of mortar through the joints in the walls.
Pumping shall not be done while concrete is being placed, or until 24 hours
thereafter. To minimise the formation of laitance, great care shall be exercised
not to disturb the concrete as far as possible while it is being deposited.
All under water concreting shall be carried out by tremie method only, using
tremie of appropriate diameter. The number and spacing of the tremies should be
worked out to ensure proper concreting. The tremie concreting when started
should continue without interruption for the full height of the member being
concreted. The concrete production and placement equipment should be
sufficient to enable the underwater concrete to be completed uninterrupted within

the stipulated time. Necessary stand-by equipment should be available for

emergency situation.
The top section of the tremie shall have a hopper large enough to hold one full
batch of the mix or the entire contents of the transporting bucket as the case may
be. The tremie pipe shall not be less than 200 mm in diameter and shall be large
enough to allow a free flow of concrete and strong enough to withstand the
external pressure of the water in which it is suspended, even if a partial vacuum
develops inside the pipe. Preferably, flanged steel pipe of adequate strength for
the job shall be used. A separate lifting device shall be provided for each tremie
pipe with its hopper at the upper end. Unless the lower end of the pipe is
equipped with an approved automatic check valve, the upper end of the pipe
shall be plugged with a wadding of gunny sacking or other approved material
before delivering the concrete to the tremie pipe through the hopper; so that
when the concrete is forced down from the hopper to the pipe, it will force the
plug (and along with it any water in the pipe) down the pipe and out of the bottom
end, thus establishing a continuous stream of concrete. It will be necessary to
raise slowly the tremie in order to allow a uniform flow of concrete, but it shall not
be emptied so that water is not allowed to enter above the concrete in the pipe.
At all times after placing of concrete is started and until all the required quantity
has been placed, the lower end of the tremie pipe shall be kept below the surface
of the plastic concrete. This will cause the concrete to build up from below
instead of flowing out over the surface and thus avoid formation of layers of
laitance. If the charge in the tremie is lost while depositing, the tremie shall be
raised above the concrete surface and unless sealed by a check valve, it shall be
replugged at the top end, as at the beginning, before refilling for depositing
further concrete.
1712 ADVERSE WEATHER CONDITIONS
1712.1 Cold Weather Concreting
Where concrete is to be deposited at or near freezing temperature, precautions

shall be taken to ensure that at the time of placing, it has a temperature of not
less than 5 degrees Celsius and that the temperature of the concrete shall be
maintained above 4 degrees Celsius until it has thoroughly hardened. When
necessary, concrete ingredients shall be heated before mixing but cement shall
not be heated artificially other than by the heat transmitted to it from other
ingredients of the concrete. Stock-piled aggregate may be heated by the use of

dry heat or steam. Aggregates shall not be heated directly by gas or on sheet
metal over fire. In general, the temperature of aggregates or water shall not
exceed 65 degrees Celsius. Salt or other chemicals shall not be used for the
prevention of freezing. No frozen material or materials containing ice shall be
used. All concrete damaged by frost shall be removed. It is recommended that
concrete exposed to freezing weather shall have entrained air and the water
consent of the mix shall not exceed 30 litres per 50 kg of cement.
1712.2 Hot Weather Conditions
When depositing concrete in very hot weather, precautions shall be taken so that
the temperature of wet concrete does not exceed 40 degrees Celsius while
placing. This shall be achieved by stacking aggregate under the shade and
keeping them moist, using cold water, reducing the time between mixing and
placing to the minimum, cooling form work by sprinkling water, starting curing
before concrete dries out and restricting concreting as far as possible to early
mornings and late evenings. When ice is used to cool mixing water, it will be
considered a part of the water in design mix. Under no circumstances shall the
mixing operation be considered complete until all ice in the mixing drum has
melted.
The Contractor will be required to slate his methodology for the Engineer's
approval when temperatures of concrete are likely to exceed 40 degrees Celsius
during the work.
1713 PROTECTION AND CURING
Concreting operations shall not commence until adequate arrangements for

concrete curing have been made by the Contractor.
Curing and protection of concrete shall start immediately after compaction of the
concrete to protect it from :
a) Premature drying out particularly by solar radiation and wind
b) High internal thermal gradients
c) Leaching out by rain and flowing water
d) Rapid cooling during the first few days after placing
e) low temperature or frost
f) Vibration and impact which may disrupt the concrete and interfere with its bond
0 the reinforcement

Where members are of considerable size and length, with high cement content,
accelerated curing methods may be applied, as approved by the Engineer.
1713.1 Water Curing
Water for curing shall be as specified in Section 1000.
Sea water shall not be used for curing. Sea water shall not come into contact with
concrete members unless it has attained adequate strength.
Exposed surfaces of concrete shall be kept continuously in a damp or wet

condition by ponding or by covering with a layer of sacks, canvas, Hessian or
similar materials and shall be kept constantly wet for a period of not less than 14
days from the date of placing of concrete.
1713.2 Steam Curing
Where steam curing is adopted, it shall be ensured that it is done in a suitable

enclosure to contain the live steam in order to minimise moisture and heat losses.
The initial application of the steam shall be after about four hours of placement of
concrete to allow the initial set of the concrete to take place.
Where retarders are used, the waiting period before application of the steam shall
be increased to about six hours.
The steam shall be at 100 per cent relative humidity to prevent loss of moisture
and to provide excess moisture for proper hydration of the cement.
The application of steam shall not be directly on the concrete and the ambient air
temperature shall-increase at a fate not exceeding 5 degrees Celsius per hour
until a maximum temperature of 60 degrees Celsius to 70 degrees Celsius is
reached. The maximum temperature shall be maintained until the concrete has
reached the desired strength.
When steam curing is discontinued, the ambient air temperature shall not drop at
a rate exceeding 5 degrees Celsius per hour until a temperature of about 10
degrees Celsius above the temperature of the air to which the concrete will be
exposed, has been reached.
The concrete shall not be exposed to temperatures below freezing for at least six
days after curing.
1713.3 Curing Compounds
Curing compounds shall only be permitted in special circumstances and will

require specific approval of the Engineer. Curing compounds shall not be used on

any surface which requires further finishing to be applied. All construction joints
shall be moist, cured and no curing compound will be permitted in locations
where concrete surfaces are required to be bonded together.
Curing compounds shall be continuously agitated during use. All concrete cured
by this method shall receive two applications of the curing compound. The first
coat shall be applied immediately after acceptance of concrete finish. If the
surface is dry, the concrete shall be saturated with water and curing compound
applied as soon as the surface film of water disappears. The second application
shall be made after the first application has set. Placement in more than two
coats may be required to prevent streaking.
1714 FINISHING
Immediately after the removal of forms, exposed bars or bolts, if any, shall be cut
inside the concrete member to a depth of at least 50 mm below the surface of the
concrete and the resulting holes filled with cement mortar. All fins caused by form
joints, all cavities produced by the removal of form ties and all other holes and
depressions, honeycomb spots, broken edges or corners, and other defects, shall
be thoroughly cleaned, saturated with water, and carefully pointed and rendered
true with mortar of cement and fine aggregate mixed in the proportions used in
the grade of concrete that is being finished and of as dry a consistency as is
possible to use. Considerable pressure shall be applied in filling and pointing to
ensure thorough filling in all voids. Surfaces which have been pointed shall be
kept moist for a period of twenty four hours. Special pre-packaged proprietary
mortars shall be used where appropriate or where specified in the drawing.
All construction and expansion joints in the completed work shall be left carefully
tooled and free from any mortar and concrete. Expansion joint Filler shall be left
exposed for its full length with clean and true edges.
Immediately on removal of forms, the concrete work shall be examined by the

Engineer before any defects are made good.
a) The work that has sagged or contains honeycombing to an extent detrimental

to structural safely or architectural appearance shall be rejected.
b) Surface defect of a minor nature may be accepted. On acceptance of such

work by the Engineer, the same shall be rectified as directed by the Engineer.

1714.1 Protective Coating on Concrete (where specified)
Inspite of measures such as extra cover to reinforcement, provision of rich &

dense concrete etc it is necessary to take preventive measures against ingress of
corrosive forces which induce weathering carbonation of concrete and spalling.
This is achieved by application of suitable paint to the surface of Reinforced
cement concrete and prestressed concrete. For concrete surface in contact with
soil coal Tar epoxy paints and for exposed concrete surfaces Anti carbonate
acrylic based paints, recommended by recognized research institutes should be
used. The paint shall be got approved by the engineer and specifications given
by manufacturing company shall be followed strictly. Before application of paint
the surface should be cleaned to remove dirt, loose particles, laitance, flaking etc.
Surface irregularities and blowhole defects shall be rectified by material
prescribed by company. Before applying primer coat surface should be cleaned
by hard brushes or sand blasting. Primer should be applied thereafter and after
8hrs second coat should be applied. Total dry thickness of film should not be less
than 190 microns. The paint shall be stored, mixed and applied by brushes or
spray as per manufacturers specifications.
1715 TOLERANCES
Tolerances for dimensions/shape of various components shall be as indicated in

these specifications or shown on the drawings or as directed by the Engineer.
1716.1 Concrete shall conform to the surface finish and tolerance as prescribed in these
specifications for respective components.
1716.2 Random sampling and lot by lot of acceptance inspection shall be made for the
28 days cube strength of concrete.
1716.2.1 Concrete under acceptance shall be notionally divided into lots for the purpose of
sampling, before commencement of work. The delimitation of lots shall be
determined by the following:
(i) No individual lot shall be more than 30 cum. in volume
(ii) At least one cube forming an item of the sample representing the lot shall be
taken from concrete of the same grade and mix proportions cast on any day.
(iii) Different grades of mixes of concrete shall be divided into separate lots

(iv) Concrete of a lot shall be used in the same identifiable component of the
bridge
1716.2.2 Sampling and testing
1. Concrete for making 3 test cubes shall be taken from a batch of concrete at
point of delivery into construction, according to procedure laid down in IS: 1199.
2. A random sampling procedure to ensure that each of the concrete batches

forming the lot under acceptance inspection has equal chance of being chosen
for taking cubes shall be adopted.
3. 150 mm cubes shall be made, cured and tested at the age of 28 days for
compressive strength in accordance with IS:516. The 28-day test strength result
for each cube shall form an item of the sample.
1716.2.3 Test specimen and sample strength : Three test specimens shall be made from
each sample for testing at 28 days. Additional cubes may be required for various
purposes such as to determine the strength of concrete at 7 days or for any other
purpose.
The test strength of the sample shall be the average of the strength of 3 cubes.
The individual variation should not be more than ± 15 per cent of the average.
1716.2.4 Frequency: The minimum frequency of sampling of concrete of each grade shall
be in accordance with Table 1700-8
TABLE 1700-8
Quantity of Concrete in work, m 3 No. of samples

1-5 1
6-15 2
16-30 3
31-50 4
4 plus one additional sample for
51 and above each additional 50 m3 or each part
thereof
At least one sample shall be taken from each shift of work.
1716.2.5 Acceptance criteria
Compressive Strength

When both the following conditions are met, the concrete complies with the
specified compressive strength:
a) The mean strength determined from any group of four consecutive samples
should exceed the specified characteristic compressive strength.
b) Strength of any sample is not less than the specified characteristic

compressive strength minus 3 MPa.
The quantity of concrete represented by the test results include the batches from
which the first and last samples were taken, together with all intervening batches.
Chloride and Sulphate Content
The total chloride and sulphuric anhydride (503) content of all the constituents of
concrete as a percentage of mass of cement in the mix shall not exceed the
values given in this section of the specifications.
1716.3 Density of Fresh Concrete
Where minimum density of fresh concrete is specified, the mean of any four
consecutive samples shall not be less than the specified value and any individual
sample result shall not be less than 97.5 per cent of the specified value.
1716.4 Density of Hardened Concrete
Where minimum density of hardened concrete is specified, the mean of any four
consecutive samples shall not be less than the specified value and any individual
sample result shall not be less than 97.5 per cent of the specified value.
1716.5 Permeability Test
The concrete should pass the following tests if it is properly compacted and is not
considered permeable.
(i) Prepare a cylindrical test specimen 150 mm dia and 160 mm dia high.
(ii) After 28 days of curing, the tests specimen is fitted in a machine such that the
specimen can be placed in water under pressure upto 7 bars. A typical machine
is shown in Appendix 1700/11.
(iii) At first a pressure of one bar is applied for 48 hours, followed by 3 bars for 24
hours and 7 bars for next 24 hours.
(iv) After the passage of the above period, the specimen is taken out and split in
the middle by compression applied on two round bars and opposite sides above
and below.

(v) The water penetration in the broken core is to be measured with a scale and
the depth of penetration assessed in mm (max. permissible limit 25 mm).
1716.6 If the concrete is not able to meet any of the standards of acceptance as
prescribed, the effect of such deficiency on the structure shall be investigated by
the Contractor as directed by the Engineer. The Engineer may accept the
concrete as sub-standard work. Any additional work required by the Engineer for
such acceptance shall be carried out by the Contractor at his cost. In case the
concrete is not found to be acceptable after investigation, the Contractor shall
remove the rejected concrete forthwith.
Structural concrete shall be measured in cubic meters. In reinforced or

pretressed concrete, the volume occupied by reinforcement or prestressing
cables and sheathing shall not be deducted. The slab shall be measured as
running continuously through and the beams as the portion below the slab.
1718 RATE
The contract unit rate for structural concrete shall cover costs of all materials,
labour, tools, plant and equipment required for mixing, transporting and placing in
position, vibrating and compacting, finishing and curing as per this Section or as
directed by the Engineer, painting with protective paint including all incidental
expenses, sampling and testing, quality assurance and supervision. Unless
mentioned separately as an item in the Contract, the contract unit rate for
concrete shall also include the cost of providing, fixing and removing form work
required for concrete work as per Section 1500.

1800 PRESTRESSING

1801 DESCRIPTION
Structural concrete containing prestressed steel reinforcement to introduce

precompression is termed as prestressed concrete.
The work shall be carried out in accordance with the drawing and these
specifications or as approved by the Engineer.
Concrete and untensioned steel for the construction of prestressed concrete

members shall conform to the requirements of sections 1700 and 1600 for
Structural Concrete and Steel Reinforcement respectively in so far as the
requirements of these Sections apply and. are not specifically modified by
requirements set forth herein.
1802 MATERIALS
1802.1 All materials shall conform to Section 1000.
1802.2 Sheathing
1802.2.1 The sheathing ducts shall be of 'the spiral corrugated type. Unless otherwise
specified, the material shall be Cold Rolled Cold Annealed (CRCA) Mild Steel
conforming to IS:513 intended for mechanical treatment and surface refining but
not for quench hardening or tempering.
The material shall normally be bright finished. However, where specified, as in

case of use in aggressive environment, galvanised or lead-coated mild steel
strips shall be used.
The thickness of sheathing shall be as shown on the drawing, but shall not be
less than 0.3 mm, 0.4 mm and 0.5 mm for sheathing ducts having internal
diameter of 50 mm, 75 mm and 90 mm respectively. For bigger diameter of
ducts, thickness of sheathing shall be based on recommendations of prestressing
system supplier or as directed by the Engineer.
The sheathing shall conform to the requirement as per tests specified in

Appendix 1800/1. for major projects, the sheathing ducts should preferably be
manufactured at the project site utilising appropriate machines. With such an
arrangement, long lengths of sheathing ducts may be used with consequent
reduction in the number of joints and couplers. Where sheathing duct joints are
unavoidable, such joints shall be made slurry tight by the use of corrugated

threaded sleeve couplers which may be tightly screwed onto the outer side of the
sheathing ducts.
The length of the coupler should not be less than 150 mm but should be
increased upto 200 mm wherever practicable. The joints between the ends of the
coupler and the duct shall be sealed with adhesive sealing tape to prevent
penetration of cement slurry during concreting. The couplers of adjacent ducts
should be staggered wherever practicable. As far as possible, couplers should
not be located in curved zones. The corrugated sleeve couplers are being
conveniently manufactured using the sheath making machine with the next higher
size of die set.
1802.2.2 The internal area of the sheathing duct shall be in accordance with the
recommendations of the system manufacturer and shall be about three times the
area of the tendons. In case of 6T13, 12T13 and 19T13 sizes of tendons
comprising 12/13 mm dia strands, the inner diameter of the sheathing shall not
be less than 50 mm, 75 mm and 90 mm respectively or those shown in the
drawing, whichever is greater.
Where prestressing tendons are required to be threaded after concreting the

diameter of sheathing shall be about 5 mm larger than that required as above.
1802.2.3 In severe environment, cables shall be threaded after concreting. In such cases a
temporary tendon shall be inserted in the sheathing or the sheathing shall be
stiffened by other suitable method during concreting.
1802.3 Anchorages
1802.3.1 Anchorages shall be procured from authorized manufacturers only. Anchorages

shall conform to 65:4447. Test certificates from a laboratory fully equipped to
carry out the tests shall be furnished to the Engineer. Such test certificates shall
not be more than 12 months old at the time of making the proposal for adoption
of a particular system for the project.
No damaged anchorages shall be used. Steel parts shall be protected from

corrosion at all times. Threaded parts shall be protected by greased wrappings
and tapped holes shall be protected by suitable plugs until used. The anchorage
components shall be kept free from mortar and loose rust and any other
deleterious coating.

1802.3.2 Swages of prestressing strand and button-heads of prestressing wire, where

provided shall develop a strength of at least 95 per cent of the specified breaking
load of the strand or wire as the case may be. Where swaging/button-heading is
envisaged, the Contractor shall furnish details of his methodology and obtain
approval of the Engineer, prior to his taking up the work.
1802.3.3 Untensioned Steel reinforcements, around anchorages shall conform to the

details of prestressing system and as shown on the drawing.
1803 TESTING OF PRESTRESSING STEEL AND ANCHORAGES
All materials specified for testing shall be furnished "free of cost and shall be
delivered in time for tests to be made well in advance of anticipated time of use.
All wire, strand or bars to be shipped to the site shall be assigned a lot number
and tagged for identification purposes. Anchorage assemblies, to be shipped
shall be like-wise identified.
All samples submitted shall be representative of the lot to be furnished and in the
case of wire or strand, shall be taken from the same master roll. The Contractor
shall furnish samples of at least 5.0 m length selected from each lot for testing.
Also, two anchorage assemblies, complete with distribution plates of each size
or types to be used, shall be furnished along with short lengths of strands as
required.
1804 WORKMANSHIP
1804.1 Cleaning
Tendons shall be free from loose rust, oil, grease, tar, paint, mud or any other
deleterious substance.
Cleaning of the steel may be carried out by immersion in suitable solvent

solutions, wire brushing or passing through a pressure box containing
carborundum powder. However, the tendons shall not be brought to a polished
condition.
1804.2 Straightening
High tensile steel wire and strand shall be supplied in coils of sufficiently large
diameter such that tendons shall retain their physical; properties and shall be
straight as it unwinds from the coil. Tendons of any type that are damaged,
kinked or bent shall not be used.

The packing of prestressing wire/strand shall be removed only just prior to

making of cable for placement. Suitable stands shall be provided to facilitate
uncoiling of wires/strands without damage to steel. Care shall be taken to avoid
the possibility of steel coming into contact with the ground.
1804.3 Positioning
1804.3.1 Post-Tensioning
Prestressing tendons shall be accurately located and maintained in position,

both vertically and horizontally, as per drawings.
Tendons shall be so arranged that they have a smooth profile without sudden
bends or kinks.
The locationing of prestressed cables shall be such as to facilitate easy

placement and vibration of concrete in between the tendons. High capacity
tendon shall be used to reduce the number of cables thereby eliminating the
necessity of grouping. The selected profiles of the tendons shall be such that
their anchorages are not located in the top deck surface. Where two or more
rows of cables have to be used, the cables shall be vertically in line to enable
easy flow of concrete. The clear vertical and horizontal distances between any
two cables shall in no case be less than 100mm anywhere along the length of
the superstructure. Where precast segments are used, the clear distance shall
be at least 150 mm.
Sheathing shall be placed in correct position and profile by providing suitable

ladders and spacers. Such ladders may be provided at intervals of approximately
1.0 m. Sheathing shall be tied rigidly with such ladders/spacer bars so that they
do not get disturbed during concreting.
The method of supporting and fixing shall be such that profile of cables is not
disturbed during vibrations, by pressure of wet concrete, by workmen or by
construction traffic.
Sheathing in which the permanent tendon will not be in place during concreting
shall have a temporary tendon inserted or shall be stiffened by some other
method to the approval of the Engineer. The temporary tendon shall be pulled out
before threading the permanent tendon into place by a special threading
machine or other contrivance.

Where possible tendons shall not be placed until immediately prior to stressing.
Tendons shall be handled with care to avoid damage or contamination, to either
the tendon or the sheathing. Any tendons damaged or contaminated shall be
cleaned or replaced.
1804.3.2 Pre-Tensioning. Prestressing steel shall be accurately located and maintained in

position, both vertically and horizontally, as per drawings.
1804.3.3 Each anchorage device shall be set square to the line of action of the
corresponding prestressing tendon and shall be positioned securely to prevent
movement during concreting.
The anchorage devices shall be cleaned to the satisfaction of the Engineer prior
to the placing of concrete. After concreting, any mortar or concrete which adheres
to bearing or wedging surfaces, shall be removed immediately.
1804.4 Cutting
Cutting and trimming of wires or strands shall be done by suitable mechanical or

flame cutters. When a flame cutter is used, care shall be taken to ensure that the
flame does not come in contact with other stressed steel. The location of flame
cutting of wire or strand shall be kept beyond 75 mm of where the tendon will be
gripped by the anchorage or jacks.
In post-tensioning the ends of prestressing steel projecting beyond the

anchorages, shall be cut after the grout has set.
1804.5 Protection of Prestressing Steel
Prestressing steel shall be continuously protected against corrosion, until

grouted. The corrosion protector shall have no deleterious effect on the steel or
concrete or. on the bond strength of steel to concrete. Grouting shall conform to
these specifications or as directed by the Engineer. In the case of external
prestressing, steel shall be encased in suitable polyethelene pipes before
grouting.
1804.6 Sheathing
The joints of all sheathings shall be water-tight. Special attention shall be paid to
the junction at the anchorage end, where the sheathing must tightly fit on the
protruding trumpet end of anchorage and thereafter sealed preferably with heat
shrink tape, to make it waterproof.

The heat-shrink tape is supplied in the form of bandage rolls which can be used
for all diameters of sheathing ducts. The bandage is coated on the underside
with a heat sensitive adhesive so that after heating the bandage material shrinks
on the sheathing duct and ensures formation of a leak-proof joint. The heating is
effected by means of a soft gas flame.
A sheath making machine should be positioned at the site of work for large
projects so that sheathing can be prepared as and when it is required for
construction.
The sheathing and all joints shall be water tight. Any temporary opening in the
sheathing shall be satisfactorily plugged and all joints between sheathing and any
other part of the prestressing system shall be effectively sealed to prevent entry
of mortar, dust, water or other deleterious matter.
Sheathing shall be neatly fitted at joints without internal projection or reduction of

diameter.
Enlarged portions of the sheathing at couplings or anchorages shall be of

sufficient length to provide for the extension of the tendons.
1804.7 Grout Vents
Grout vents of at least 20 mm diameter shall be provided at both ends of the

sheathing and at all valleys and crests along its length. Additional vents with
plugs shall also be provided along the length of sheathing such that the spacings
of consecutive vents do not exceed 20 m. Each of the grout vents shall be
provided with a plug or similar device capable of withstanding a pressure of 1.0
M Pa without the loss of water, air pressure or grout.
1804.8 Anchorages
All bearing surfaces of the anchorages shall be cleaned prior to concreting and
tensioning.
Anchor cones, blocks and plates shall be securely positioned and maintained
during concreting such that the centre line of the duct passes axially through the
anchorage assembly.
The anchorages shall be recessed from the concrete surface by a minimum

cover of 100 mm.
After the prestressing operations are completed and prestressing wires/strands

are cut, the surface shall be painted with two coats of epoxy of suitable

formulation having a dry film thickness of 80 microns per coat and entire recess
shall be filled with concrete or non-shrink/pre-packaged mortar or epoxy
concrete.
1804.9 Structural Concrete
Structural concrete shall conform to Section 1700. The formwork shall conform to
Section 1500.
1805 SUPERVISION
All prestressing and grouting operations shall be undertaken by trained personnel

only. A representative of supplier of the prestressing system shall be present
during all tensioning and grouting operations and shall ensure, monitor and
certify their correctness.
1806 TENSIONING EQUIPMENT
All tensioning equipment shall be procured from authorised manufacturers only

and be approved by the Engineer prior to use. Where hydraulic jacks are used,
they shall be power-driven unless otherwise approved by the Engineer. The
tensioning equipment shall satisfy the following requirements:
(i) The means of attachments of the prestressing steel to. the jack or any other
tensioning apparatus shall be safe and secure.
(ii) Where two or more wires/strands constitute a tendon, a single multipull

stressing jack shall be used which is capable of tensioning simultaneously all the
wires/ strands of the tendon. Suitable facilities for handling and attaching the
multi-pull jack to the tendons shall be provided.
(iii) The tensioning equipment shall be such that it can apply controlled total force
gradually on the concrete without inducing dangerous secondary stresses in
steel, anchorage or concrete; and
(iv) Means shall be provided for direct measurement of the force by use of
dynamometers or pressure gauges fitted in the hydraulic system itself to
determine the pressure in the jacks. Facilities shall also be provided for the linear
measurement of' the extension of prestressing steel to the nearest mm and of
any slip of the gripping devices at transfer. All dynamo meters and pressure
gauges including a master gauge shall be calibrated by an approved laboratory
immediately prior to use and then at intervals not exceeding 3 months and the
true force determined from the calibration curve.

Pressure gauges shall be concentric scale type gauges accurate to within two per
cent of their full capacity. The minimum nominal size of gauge shall be 100 mm.
The gauge shall be so selected that when the tendon is stressed to 75 per cent of
its breaking load, the gauge is reading between 50 per cent and 80 per cent of its
full capacity.
Suitable safety devices shall be fitted to protect pressure gauges against sudden
release of pressure.
Provision shall be made for the attachment of the master gauge to be used as a
check whenever requested for by the Engineer.
1807 POST-TENSIONING
Tensioning force shall be applied in gradual and steady steps and carried out in
such a manner that the applied tensions and elongations can be measured at all
times. The sequence of stressing, applied tensions and elongations shall be in
accordance with the approved drawing or as directed by the Engineer.
It shall be ensured that in no case, the load is applied to the concrete before it
attains the strength specified on the drawing or as stipulated by the prestressing
system supplier, whichever is more.
After prestressing steel has been anchored, the force exerted by the tensioning
equipment shall be decreased gradually and steadily so as to avoid shock to the
prestressing steel or anchorage.
The tensioning force applied to any tendon shall be determined direct reading of
the pressure gauges or dynamo-meters and by comparison of the measured
elongation with the calculated elongation. The calculated elongation shall be
invariably adjusted with respect to the modulus of elasticity of steel for the
particular lot as given by the manufacturer.
The difference between calculated and observed tension and elongation during
prestressing operations shall be regulated as follows:
a) If the calculated elongation is reached before the specified gauge pressure is

obtained, continue tensioning till attaining the specified gauge pressure, provided
the elongation does not exceed 1.05 times the calculated elongation. If 1.05
times the calculated elongation is reached before the specified gauge pressure is
attained, stop stressing and inform the Engineer.

b) If the calculated elongation has not been reached at the specified gauge
pressure, continue tensioning by intervals of 5 kg/sq. cm. until the calculated
elongation is reached provided the gauge pressure does not exceed 1.05 times
the specified gauge pressure.
c) If the elongation at 1.05 times the specified gauge pressure is less than 0.95
times the calculated elongation, the following measures must be taken, in
succession, to determine the cause of this lack of discrepancy
i) Check the correct functioning of the jack, pump and leads.
ii) Detension the cable. Slide it in its duct to check that it is not blocked by mortar
which has entered through holes in the sheath. Retension the cable if free.
iii) Re -establish the modulus of elasticity of steel for the particular lot from an
approved laboratory.
If the required elongation is still not obtained, further finishing operations such as
cutting or sealing, should not be undertaken without the approval of the
Engineer.
d) When stressing from one end only, the slip at the end remote from the jack
shall be accurately measured and an appropriate allowance made in the
measured extension at the jacking end.
A complete record of prestressing operations along with elongation and jack

pressure data shall be maintained in the format given in Appendix 1800/11. The
,lumber of stages of prestressing and grouting shall be reduced to a minimum,
preferably 2 in the case of simply supported girders.
1808 GROUTING OF PRESTRESSED TENDONS
Grouting shall conform to Appendix 1800/11. A record of grouting operation shall

be maintained in the format given in Appendix l800/IV.
1809 PRE-TENSIONING
1809.1 Genera!
The planning and construction aspects of the tensioning bed, tensioning bench,
abutments at location of anchorage, steam curing system, form work of the
concrete elements and arrangements for de-moulding, lifting, stacking and
transportation of the pre-tensioned concrete elements are all specialised items
and shall be entrusted to engineers specifically experienced in this type of work

1809.2 Stressing Bed for Pre-tensioning
The abutments and bed for pre-tensioning of tendons shall be designed to

withstand the total tensioning force.
A notice shall be displayed adjacent to the stressing bed showing the maximum
tensioning force permitted.
Where concrete elements are cast and prestressed individually, the stressing
bench or moulds shall be rigid enough to sustain the reaction of the prestressing
force without distortion.
In the long line method of prestressing, sufficient locator plates should be

distributed throughout the length of the bed to ensure that the wires are
maintained in their proper position during concreting. The moulds shall be free to
slide in 'the direction of their length and thus permit the transfer of the
prestressing force to all the concrete elements along the whole line.
Sufficient space shall be left in between the ends of concrete elements to permit
access for cutting the strands/wires after transfer. Hold-downs or deflectors shall
be used for holding or deflecting the tendons in required position firmly.
Deflectors which are in contact with the tendon shall have a diameter not less
than the tendon or 15 mm, whichever is greater.
The tensioning force required to be applied as stated on the drawings shall be the
force remaining in the strands/wires after all strands/wires have been anchored to
the abutments of the stressing bed and after the anchorage slip has already
taken place. The tensioning force shall be determined by direct reading of the
pressure gauges or dynamo-meters and by the measured elongation after slip.
The Contractor shall submit method of tensioning the tendons including the
arrangement and layout of prestressing beds and all tendon deflection points to
the Engineer for approval before manufacture commences.
The Contractor shall carry out trial stressing operations to establish the frictional
resistance offered by the hold-downs and the slip during anchoring. Where
sheathing of pre-tensioned tendons is required to prevent bond over a specified
length, it shall consist of plastic tubing or other material approved by the
Engineer and shall be of a quality, diameter and thickness such that bond shall
be effectively prevented. The tubing shall be fastened to the tendon in such a
manner that cement mortar cannot enter. The Engineer may order that the pull-in
of the tendon be measured during the transfer of prestress.

The Contractor shall also submit calculations showing that the hold downs have
been designed and constructed to withstand concentrated loads resulting from
the application of the tensioning force.
1809.3 Tensioning Procedure
The tensioning of the wires and strands shall be done not too much in advance
of concreting.
The tensioning force shall be applied gradually and uniformly.
In order to remove slack and to lift tendons off the bed floor, an initial force
approved by the Engineer shall be applied to the tendons. Allowance shall be
made for this force in calculating the required elongation.
Tendons shall be marked for measurement of elongation after the initial force has
been applied. When required by the Engineer, tendons shall be marked at both
the jacking end and dead end of the stressing bed and at couplers if used so that
slip and draw-in may be measured.
Where deflected strands have been specified, the Engineer may direct the
elongation or strain gauge measurements be taken at various positions along the
tendon to determine the force in the tendon at those positions.
1809.4 Transfer of Prestress
While the process of tensioning can be accomplished by means of hydraulic

jacks, some positive mechanical means shall be provided to maintain the tension
during .the entire period between the tensioning of the wires/strands and transfer
of the prestressing force to the concrete element.
Transfer of prestress shall not proceed until the Engineer has approved the
proposed method. Tendons and deflection devices shall be released in such a
pre-determined order that unacceptable tensile stresses are not induced in the
concrete.
Prior to transfer of the force to the units, all tendons shall be tested for tightness
and any loose tendon shall be reported to the Engineer who will decide whether
the units affected shall be rejected.
The Engineer may require that tendons be marked at each end of any unit to
allow measurement of the pull-in of the concrete.
Tendons shall be released gradually and preferably simultaneously. Under no

circumstances shall tendons be cut while under tension.

On completion of the transfer of prestress, the projecting lengths of tendon shall

be cut off flush with the end surface of the unit, unless otherwise shown, by a
method approved by the Engineer.
In no case shall the transfer of prestressing force to the concrete elements take
place before concrete attains the strength specified in the drawings. To determine
the specified strength, additional cube testing shall be undertaken at the
Contractor's cost. In case steam curing is employed, the cubes shall be placed in
the same environment as the concrete elements to obtain an accurate
assessment of concrete strength at the time of transfer.
The sequence of transfer of prestressing force shall be done strictly as indicated

in the drawings and ensuring that eccentricities of the prestressing force in the
vertical and horizontal directions of the concrete element is a minimum during
the entire sequence.
The maximum slip of any tendon during transfer shall not exceed 3 mm at any
end of the concrete element. in case this slip is exceeded, the concrete element
in question shall be rejected.
1809.5 Protection of Ends
The exposed ends of the tendons and the 'concrete surfaces of the ends of the
units shall be wire brushed dean of all rust, loose mortar, grease and dirt.
The exposed ends of the tendons and concrete surface within 50 mm of tendons
shall be then abraded to provide a dean sound surface. An epoxy tar paint
suitably formulated to give a dry film thickness of 80 microns per coat shall then
be immediately applied over the ends of the tendons unless otherwise directed.
A second coat of paint shall be applied prior to the drying out of the first coat.
1810 SAFETY PRECAUTIONS DURING TENSIONING
Care shall be taken during tensioning to ensure the safety of all person in the
vicinity.
Jacks shall be secured in such a manner that they will be held in position, should
they lose their grip on the tendons.
No person shall be allowed to stand behind the jacks or dose to the line of the
tendons while tensioning is in progress.

The operations of the jacks and the measurement of the elongation and
associated operations shall be carried out in such a manner and from such a
position that the safety of all concerned is ensured.
A safety barrier shall be provided at both ends to prevent any tendon, which
might become loose from recoiling unchecked.
During actual tensioning operation, warning sign shall be displayed at both ends
of the tendon.
After prestressing, concrete shall neither be drilled nor any portion cut nor
chipped away nor disturbed, without express approval of the Engineer.
No welding shall be permitted on or near tendons nor shall any heat be applied
to tendons. Any tendon which has been affected by welding, weld spatter or heat
shall be rejected.
1811 TRANSPORTATION AND STORAGE OF UNITS
Precast girders shall be transported in an upright position. Points of support and

the direction of reactions with respect to the girder shall approximately be the
same during transportation, and storage as when the girder is placed in final
position.
When members are to be stacked, they shall be firmly supported at such bearing
positions as will ensure that the stresses induced in them are always less than
the permissible design stresses. Further, inclined side supports shall be provided
at the ends and along the length of a precast girder to prevent lateral movements
or instability.
Care shall be taken during storage,-hoisting and handling of the precast units to
prevent their cracking or being damaged. Units damaged by improper storing or
handling shall be replaced by the Contractor at his expense.
1812 TOLERANCES
Permissible tolerances for positional deviation of Prestressing tendons shall be

limited to the following:
a) Variation from the specified horizontal profile: 5mm
b) Variation from the specified vertical profile: 5mm
c) Variation from the specified position in member: 5mm

Prestressed Concrete shall be measured in cubic metres. The volume occupied

by mild steel reinforcement! HYSD bars, high tensile steel, sheathing and
anchorages shall not be deducted.
High tensile (prestressing) steel shall be paid for separately and its length shall
be measured as actually incorporated in the finished work. From the length so
measured its weight shall be calculated in tonnes on theoretical basis and paid
for.
Anchorage devices, additional length of cables for attaching jack, ducts or

sheathing, grout, non-prestressed steel reinforcement fixed to the anchorage
devices, making of recesses and filling the same, protection by painting with
epoxy and furnishing samples for testing shall all be deemed to be included in
the item of high tensile steel and shall not be measured separately.
1815 RATE
The contract unit rate for cast-In-place prestressed concrete shall cover the cost
of all materials, labour, tools and plant required for mixing, placing in position,
vibrating and compacting, finishing as per directions of the Engineer, curing and
other incidental expenses for producing concrete of specified strength to
complete the structure or its components as shown on the drawings and
according to specifications. The contract unit rate shall also include the cost of
making, fixing and removing of all centring and forms required for the work
unless otherwise specified in the Contract.
For precast prestressed concrete members, the rate in addition to above shall
also include the cost of all materials, labour, tools and plant required to transport
and place these members in their final position as shown on the drawings and as
directed by the Engineer.
The contract unit rate for high tensile steel shall cover the cost of material,
labour, tools and plant required for manufacturing, placing, tensioning, anchoring

and grouting the high tensile steel in the prestressed concrete as shown on the
drawings and as per specifications herein above or as directed by the Engineer.
The cost of anchorage devices, additional length of cables for attaching jack,
ducts or sheathing, grout, non-prestressed steel reinforcement fixed to the
anchorage devices, making of recesses and filling the same, protection by
painting with epoxy and furnishing samples for testing shall all be included in the
unit rate. Rate shall also include payments if any to be made to the supplier of
the prestressing system who has to monitor, ensure and certify the correctness
of all operations.

1900 STRUCTURAL STEEL

1901 DESCRIPTION
This work shall include furnishing, fabricating, transporting, erecting and painting
structural steel, rivet steel, cast steel, steel forgings, cast iron and other
incidental metal construction of the kind, size and quantity in conformity with the
drawings and these specifications or as desired by the Engineer.
1902 GENERAL
General requirements relating to the supply of material shall conform to,the

specifications of IS: 1387, for the purpose of which the supplier shall be the
Contractor and the purchaser shall be the Engineer.
Finished rolled material shall be free from cracks, flaws, injurious seams, laps,
blisters, ragged and imperfect edges and other defects. It shail have a smooth
and uniform finish, and shall be straightened in the mill before shipment. They
shall also be free from loose mill scale, rust, pits or other defects affecting its
strength and durability.
The acceptance of any material on inspection at the mill i.e. rolling mills, foundry
or fabricating plant where material for the work is manufactured, shall not be a
bar to its subsequent rejection, jf found defective.
Unless specified otherwise, high tensile steel rivet conforming to IS: 1149 shall
be used for members of high tensile steel conforming to IS:961 and shall not be
used for mild steel members.
Unless specified otherwise, bolted connection of structural joints using high

tensile friction grip bolts shall comply with requirements of IS:4000. Cast iron
shall not be used in any portion of the bridge structure, except where it is subject
to direct compression.
1903 MATERIALS
1903.1 All materials shall conform to Section 1000. Special requirements are given
below:
Mild steel for bolts and nuts shall conform to IS:226 but have a minimum tensile
strength of 44 kg/sq. mm. and minimum percentage elongation of 14. High
tensile steel for bolts and nuts shall conform to IS:961 but with a minimum tensile
strength of 58 kg/sq. mm. High strength friction grip bolts shall be permitted for
use only on satisfactory evidence of performance to the requirements (not

covered by these specifications) specified by the Engineer or included in the

special provisions.
For cast steel, the yield stress shall be determined and shall not be less than 50
per cent of the minimum tensile strength.
Plain washers shall be of steel. Tapered or other specially shaped washers shall
be of steel, or malleable cast iron.
Parallel barrel drifts shall have a tensile strength not less than 55 kg/sq.mm. with
elongation of not less than 20 per cent measured on a gauge length of 4VSo (So
= cross sectional area).
1903.2 Materials for castings and forgings, fasteners and welding consumables shall be
as under:
1903.2.1 Castings and Forgings : Steel castings and forgings shall comply with the
requirements of the following Indian Standards, as appropriate:
IS: 1030 Carbon Steel Castings for General Engineering purposes
IS: 1875 Carbon Steel Billets, blooms, slabs, bars for forgings
1S:2004 Carbon Steel Forgings for General Engineering purposes
1S:2644 High Tensile Steel Casings
1S:4367 Alloy & tool steel forgings for general industrial use
1903.2.2 Fasteners: Bolts, nuts, washers and rivets shall comply with the or relevant IS
Standards as appropriate:
IS: 1929 Hot forged steel rivets for hot dosing (12-36mm dial
IS:2155 Cold forged steel rivets for hot dosing (6-16mm dial
IS: 1363 Hexagon head bolts, screw and nuts product grade C
IS: 1364 Hexagon head bolts, screw & nuts product grade A & B
IS: 1367 Technical supply conditions for threaded steel fastener (Parts 1 to 18)
IS:3640 Hexagon fit bolts
IS:3757 High tensile friction grip bolts
IS:6623 High strength structural nuts
IS:6639 Hexagon bolts for steel structure

IS:5624 Foundation bolts
IS:7002 Prevailing torque type steel hexagon lock nuts
IS:5369 Plain washers and lock washers - general requirements
IS:5370 Plain washers with outside dia = 3 X inside dia
IS:5372 Taper washers for channels (ISMC)
IS:5374 Taper Washers for I beams (ISM B)
IS:6610 Heavy washers for steel structures
IS:6649 Hardened and tempered washers for high strength structural bolts and
nuts
1903.2.3 Welding consumables
Welding consumables shall comply with the following Indian Standards as

appropriate:
IS: 814 Covered Electrodes for Metal Arc Welding of structural {Part I} steel for
welding other than sheets
IS:814 For welding sheets (Part 2)
IS: 1278 Filler rods and wires for gas welding
IS: 1395 low and medium alloy Steel covered electrodes for manual Metal Arc
Welding
IS:3613 Acceptance Tests for wire flux combinations for submerged arc welding
of structural steel
IS:7280 Bare wire electrodes for gas shielded arc welding of structural steel
IS:6419 Welding rods and bare electrodes for gas shielded arc welding of
structural steel
IS:6560 Molybdenum and chromium-molybdenum low alloy steel welding rods

and bare electrodes for gas shielded arc welding

1903.3 In an aggressive environment, corrosion resistant steel can be used. These are
low-alloyed steels containing a total of 1 per cent - 2 per cent alloys, in particular,
copper, chromium, nickel and phosphorous.
1903.4 Paints
All materials for paints and enamels shall conform to the requirements specified
on the drawings or other special provisions laid down by the Engineer.
The type of paints which can be used shall be as follows:
a) Ordinary i.e. paints based on drying oils, alkyd resin, modified alkyd resin,
phenolic varnish epoxy
b) Chemical Resistant - one pack type (ready for use) and two pack type (mixed
before use).
c) Vinyl
d) Chlorinated rubber
e) Bituminous
f) Epoxy
g) Polyurethane
h) Zinc rich
Unless otherwise specified, paints shall conform to the relevant IS specifications.

The paints which have been tested for the following qualities as per specifications
given in the relevant IS codes only shall be used: Weight test (weight for 10 litre
of paint, thoroughly mixed)
Drying time
Consistency
Dry thickness and rate of consumption.
1904 FABRICATION
1904.1 General
All work shall be in accordance with the drawings and as per these specifications
with care being taken that all parts of an assembly fit accurately together. All
members shall carry mark number and item number and, if required, serial
number.

Unless specifically required under the contract, corresponding parts need not be
interchangeable, but the parts shall be match marked as required under Clause
1904.7.
Templates, jigs and other appliances used for ensuring the accuracy of the work
shall be of mild steel; where specially required, these shall be bushed with hard
steel. All measurements shall be made by means of steel tape or other device
properly calibrated. Where bridge materials have been used as templates for
drilling, these shall be inspected and passed by the Engineer before they are
used in the finished structure.
All structural steel members and parts shall have straight edges and blunt
surfaces. If necessary, they shall be straightened or flattened by pressure unless
they are required to be of curvilinear forms. They shall also be free from twist.
Pressure applied for straightening or flattening shall be such as would not injure
the materials. Hammering shall not be permitted. Adjacent surfaces or edges
shall be in dose contact or at uniform distance throughout.
The Contractor shall submit his programme of work to the Engineer for his
approval at least 15 days before the commencement of fabrication. This
programme shall include the proposed system of identification and erection
marks together with complete details of fabrication and welding procedures. The
Contractor shall prepare shop drawings for fabricating any member and obtain
approval of the Engineer before the start of work. Complete information regarding
the location, type, size and extent of all welds shall be dearly shown on the shop
drawings. These drawings shall distinguish between shop and field welds.
1904.2 Preparation of Edges and Ends
All structural- steel-parts, where required, shall be sheared, cropped, sawn or

flame cut and ground accurately to the required dimension and shape.
End/edge planing and cutting shall be done by anyone of the following prescribed
methods or left as rolled:
a) Shearing, cropping, sawing, machining, machine flame cutting.
b) Hand flame cutting with subsequent grinding to a smooth edge.
c) Sheared edges of plate not more than 16 mm thick with subsequent grinding to
smooth profile, which are for secondary use such as stiffeners and gussets.

If ends of stiffeners are required to be fitted, they shall be ground, so that the
maximum gap over 60 per cent of the contact area does not exceed 0.2.5 mm.
Where flame cutting or shearing is used, at least one of the following

requirements shall be satisfied.
a) The cut edge is not subjected to applied stress.
b) The edge is incorporated in weld.
c) The hardness of cut edge does not exceed 350 HV30.
d) The material is removed from edge to the extent of 2 mm or minimum

necessary, so that the hardness is less than 350 HV 30.
e) Edge is suitably heat treated by approved method to the satisfaction of the

Engineer and shown that cracks had not developed by dye penetrant or magnetic
particle test.
f) Thickness of plate is less than 40 mm for machine flame cutting for materials
conforming to IS:226 and IS:2062. The requirement of hardness below 350 HV
30 of flame cut edges should be specified by the Engineer.
Wherever specified by the Engineer, the flame cut edges shall be ground or
machined over and above the requirement (a) to (f)
Where machining for edge preparation in butt joint-is specified, the ends shall be
machined after the members have been fabricated.
Outside edges of plate and section, which are prone to corrosion shall be
smoothed by grinding or filing.
In the case of high tensile steel at least 6 mm of the material from the flame cut
edge shall be removed by machining.
Longitudinal edges of all plates and cover plates in plate girders and built-up
members shall be machined except in the following cases:
a) Rolled edges of single universal plates or fiats may not be machined.
b) Covers to single flange plates may be left un machined.
c) Machine flame cutting instead of machining is acceptable for edges of single

plates in compression and for edges of single plates, 25 mm or less thick, in
tension.

d) Edges of single shaped plates over 25 mm thick not capable of being

machined by ordinary method may be machine flame cut and the end surface
ground.
e) Edges of universal plates or fiats of the same nominal width used in tiers may
be left unmachined, if so authorised by the Engineer.
All edges of splice and gusset plates 12 mm thick and over shall be machined
and those less than 12 mm thick may be sheared and ground.
The ends of plates and sections forming the main components of plate girders or
of built-up members shall be machined, machine flame cut, sawn or hand flame
cut and ground.
Where ends of stiffeners are required to be fitted, they shall be machined,

machine flame cut, sawn, sheared and ground, or hand flame cut and ground.
The ends of lacing bar shall be rounded unless otherwise required.
Other edges and ends of mild steel parts may be sheared and any burrs at edges
shall be removed.
1904.3 Preparation of Holes
1904.3.1 Drilling and punching: Holes for rivets, black bolts, high strength bolts and
countersunk bolts/rivets (excluding close tolerance and turn fitted bolts) shall be
either punched or drilled. The diameter of holes shall be 1.5 mm larger for
bolts/rivets less than 25 mm dia and 2.0 mm for more than or equal to 25 mm.
All holes shall be drilled except for secondary members such as, floor plate, hand
rails etc. Members which do not carry the main load can be punched subject to
the thickness of member not exceeding 12 mm for material conforming to IS:226.
Holes through more than one thickness of material or when any of the main
material thickness exceeds 20 mm for steel conforming to IS:2062 or 16 mm for
steel conforming to IS:961, IS:8500, shall either be sub-drilled or sub-punched to
a diameter of 3 mm less than the required size and then reamed to the required
size. The reaming of material more than one thickness shall be done after
assembly.
Where several plates or sections form a compound member, they shall, where
practicable, be firmly connected together by clamps or tacking bolts, and the
holes be drilled through the group in one operation. Alternatively, and in the case
of repetition work, the plates and sections may be drilled separately from jigs and

templates. Jigs and templates shall be checked at least once after every 25
operations. All burrs shall be removed. In the case of repetition of spans, the
erection of every span shall not be insisted upon, except where dose tolerance or
turned bolts are used, provided that methods are adopted to ensure strict
interchangeability. In such cases, one span in ten or any number less than ten of
each type shall be erected from pieces selected at random by the Engineer and
should there be any failure of the pieces to fit, all similar spans shall be erected
complete. In the event of spans being proved completely interchangeable, all
corresponding parts shall carry the same mark so that sorting of the materials at
site is facilitated.
1904.3.2 Block drilling: Where the number of plates to be riveted exceeds three or the total
thickness is 90 mm or more, the rivet holes, unless they have been drilled
through steel bushed jigs, shall be drilled out in place 3 mm all round after
assembling. In such cases, the work shall be thoroughly bolted together.
1904.3.3 Size of holes: The sizes of holes in millimetres are given in Table 1900-1 below:
TABLE 1900-1 : DIAMETER OF HOLES FOR RIVETS
Nominal dia of Rivets Dia of Holes (mm)

(mm)
12 13.5
14 15.5
16 17.5
18 19.5
20 21.5
22 23.5
24 25.5
27 29.0
30 32.0
33 35.0
1904.3.4 Close tolerance bolts and barrel bolts : Holes for close tolerance and turn fitted
bolts. The diameter of the holes shall be equal to the nominal diameter of the bolt
shank minus 0.15 mm to 0.0 mm.
The members to be connected with close tolerance or turn fitted bolts shall be
firmly held together by service bolts or clamped "and drilled through all

thicknesses in one operation and subsequently reamed to required size within

specified limit of accuracy as specified in IS:919 tolerance grade H8.
The holes not drilled through all thicknesses at one operation shall be drilled to
smaller size and reamed after assembly.
1904.3.5 Holes for high strength friction grip bolts: All holes shall be drilled after removal of
burrs. Where the number of plies in the grip does not exceed three, the diameters
of holes shall be 1.6 mm larger than those of bolts and for more than three plies
in grip, the diameters of hole in outer plies shall be as above and dia of holes in
inner plies shall not be less than 1.6 mm and not more than 3.2 mm larger than
those in bolts, unless otherwise specified by the Engineer.
1904.3.6 Removal of burrs: The work shall be taken apart after drilling and all burrs left by
drilling and the sharp edges of all rivet holes completely removed.
1904.4 Rivet and Riveting
The diameter of rivets shown on the drawings shall be the ·size before heating.
Each rivet shall be of sufficient length to form a head of the standard dimensions
as given in IS handbook on Steel Sections, Part I. It shall be free from burrs on
the underside of the head.
When countersunk heads are required, the heads shall fill the countersunk. The
included angle of the head shall be as follows:
a) for plates over 14 mm thickness 90 degrees
b) for plates upto and including 14 mm thickness 120 degrees
The tolerance on the diameter of rivets shall be in accordance with IS:
1148 and IS: 1149 for mild steel rivets and high tensile steel rivets respectively
and unless otherwise specified, the tolerance shall be minus tolerance.
Rivets shall be driven when hot so as to fill the hole as completely as possible
and shall be of sufficient length to" form a head of standard dimension. When
counter-sunk head is required, the head shall fill the counter-sunk hole.
Projection after counter-sinking shall be ground off wherever necessary.
Rivets shall be heated uniformly to a "light cherry red" colour between 650
degrees Celsius to 700 degrees Celsius for hydraulic riveting and "orange colour"
for pneumatic riveting of mild steel rivets and shall be red hot from head to the
point when inserted and shall be upset in its entire length so as to fill the hole as

completely as possible when hot. Rivets, after being heated and before being
inserted in the hole shall be made free from scale by striking the hot rivet on a
hard surface.
Wherever possible, the rivets shall be machine driven, preferably by direct acting
riveters. The driving pressure shall be maintained on the rivets for a short time
after the upsetting is completed. High tensile steel rivets shall be heated upto
1100 degrees Celsius. Any rivet whose point is heated more than prescribed,
shall not be driven.
Where flush surface is required, any projecting metal shall be chipped or ground
off.
Before riveting is commenced, all work shall be properly bolted up so that the
various sections and plates are in dose contact throughout Drifts shall only be
used for drawing the work into position and shall not be used to such an extent as
to distort the holes. Drifts of a larger size than the nominal diameter of the hole
shall not be used. The riveting shall be done by hydraulic or pneumatic machine
unless otherwise specified by the Engineer.
Driven rivets, when struck sharply on the head by a quarter pound rivet testing
hammer, shall be free from movement and vibrations. Assembled riveted joint
surfaces, including those adjacent to the rivet heads, shall be free from scale,
dirt, loose scale, burrs, other foreign materials and defects that would prevent
solid seating of parts.
All loose or burnt rivets and rivets with cracked or badly formed defective heads
or with heads which are unduly eccentric with the shanks, shall be removed and
replaced. In removing rivets, the head shall be sheared off and the rivet punched
out so as not to injure the adjacent metal and, if necessary, they shall be drilled
out. Recupping or recaulking shall not be permitted. The parts not completely
riveted in the shop shall be secured by bolts to prevent damage during transport
and handling.

1904.5 Bolts, Nuts and Washers
1904.5.1 Black bolts (black all over); Black bolts are forged bolts in which the shanks,
heads and nuts do not receive any further treatment except cutting of screw
threads. They shall be true to shape and size and shall have the standard
dimensions as shown on the drawings.
1904.5.2 Close tolerance bolts: Close tolerance bolts shall be faced under the head and
turned on the shank.
1904.5.3 Turned barrel bolts: The diameter of the screwed portion of turned barrel bolts
shall be 1.5 mm smaller than the diameter of the barrel unless otherwise
specified by the Engineer. The diameter of the bolts as given on the drawing shall
be the nominal diameter of the barrel. The length of the barrel shall be such that it
bears fully on all the parts connected. The threaded portion of each bolt shall
project through the nut by at least one thread. Faces of heads and nuts bearing
on steel work shall be machined.
1904.5.4 High strength friction bolts and bolted connections: The general requirement shall
be as per relevant 15 specifications mentioned in clause 5.3 of (Fasteners) of
IRC:24. Unless otherwise specified by the Engineer, bolted connections of
structural joints using high tensile friction grip bolts shall comply with
requirements mentioned in IS:4000.
1904.5.5 Washers: In all cases where the full bearing area of the bolt is to be developed,
the bolt shall be provided with a steel washer under the nut of sufficient thickness
to avoid any threaded portion of the bolt being within the thickness of the parts
bolted together and to prevent the nut when screwed up, from bearing on the
bolt.
For dose tolerance or turned barrel bolts, steel washers whose faces give a true
bearing shall be provided under the nut. The washer shall have a hole diameter
not less than 1.5 mm larger than the barrel and a thickness of not- less than 6
mm so that the nut when screwed up, will not bear on the shoulder of the bolt.
Taper washers with correct angle of taper shall be provided under all heads and
nuts bearing on bevelled surfaces.
Spring washers may be used under nuts to prevent slackening of the nuts when
excessive vibrations occur.

Where the heads or nuts bear on timber, square washers having a length of each
side not less than three times the diameter of bolts or round washers having a
diameter of 3 1/2 times the diameter of bolts and with a thickness not less than
one quarter of diameter shall be provided
1904.5.6 Studs: Ordinary studs may be used for holing parts together, the holes in one of
the parts being tapped to take the thread of the stud. Counter-sunk studs may be
used for making connections where the surfaces are required to be clear of all
obstruction, such as protruding heads of bolts or rivets, studs may also be welded
on the steel work in the positions required.
1904.5.7 Service bolts: Service bolts shall have the same clearance as black bolts and
where it is required that there Should be no movement prior to final riveting,
sufficient drifts or dose tolerance bolts shall be used to locate the work.
1904.5.8 Tightening bolts: Bolted connection joints with black bolts and high strength bolts
shall be inspected for compliance of codal requirements.
The Engineer shall observe·the installation and tightening of bolts to ensure that
correct tightening procedure is used and shall determine that all bolts are
tightened. Regardless of tightening method used, tightening of bolts in a joint
should commence at the most rigidly fixed or stiffest point and progress towards
the free edges, both in initial snugging and in final tightening.
The tightness of bolts in connection shall be checked by inspection wrench,

which can be torque wrench, power wrench or calibrated wrench.
Tightness of 10 per cent bolts, but not less than two bolts, selected at random in
each connection shall be checked by applying inspection torque. If no nut or bolt
head is turned by this application, connection can be accepted as properly
tightened, but if any nut or head has turned an bolts shall be checked and, if
necessary, re-tightened.

1904.5.9 Drifts: The barrel shall be drawn or machined to the required diameter for a
length of not less than one diameter over the combined thickness of the metal
through which the drifts have to pass. The diameter of the parallel barrel shall be
equal to the nominal diameter of the hole subject to a tolerance of +0 mm and -
0.125 mm. Both ends of the drift for a length equal to 1 1/2 times the diameter of
the parallel portion of the bar shall be turned down with a taper to a diameter at
the end equal to one-half that of parallel portion.
1904.6 Pins and Pin Holes
1904.6.1 Pins: The pins shall be parallel throughout and shall have a smooth surface free
from flaws. They shall be of sufficient length to ensure that all parts connected
thereby shall have a full bearing on them. Where the ends are threaded, they
shall be turned to a smaller diameter at the ends for the thread and shall be
provided with a pilot nut, where necessary, to protect the thread when being
drawn to place.
Pins more than 175 mm in length or diameter shall be forged and annealed.
1904.6.2 Pin holes: Pin holes shall be bored true to gauge, smooth, straight at right
angles to the axis of the member and paranel with each other, unless otherwise
required. The tolerance in the length of tension members from outside to outside
of pin holes and of compression members from inside to inside of pin holes shall
be one millimetre. In built-up members, the boring shall be done after the
members have been riveted or welded.
The specified diameter of the pin hole shall be its minimum diameter. The
resulting clearance between the pin and the hole shall not be less than 0.5 mm
and not more than 1.0 mm.
1904.7 Shop Erection and Match Marking
Before being dispatched, the steel work shall be temporarily erected in the
fabrication shop for inspection by the Engineer either wholly or in such portion as
the Engineer may require so that he may be satisfied both in respect of the
alignment and fit of all connections. For this purpose, sufficient number of parallel
drifts and service bolts tightlv screwed up shall be employed. All parts shall fit
accurately and be in accordance with drawings and specifications.
The steel work shall be temporarily assembled at place of fabrication.

Assembly shall be of full truss or girder, unless progressive truss or girder

assembly, full chord assembly, progressive chord assembly or special complete
structure assembly is specified by the Engineer.
The field connections of main members of trusses, arches, continuous beams,

spans, bends, plate girders and rigid frame assembled, aligned accuracy of holes
and camber shall be checked by Engineer and then only reaming of sub-size
holes to specified size shall be taken up.
After the work has been passed by the Engineer and before it is dismantled, each
part shall be carefully marked for re-erection with distinguishing marks and
stamped with durable markings. Drawings showing these markings correctly shall
be supplied to the Engineer.
Unloading, handling and storage of steel work. as per these specifications shall
be the responsibility of the Contractor. The cost of repairs or of rejected material,
its removal and the cost of transporting replacement material to the site shall be
borne by the Contractor.
Where dose tolerance or turned barrel bolts are used for those cases where
interchangeabiiity is not insisted upon, each span shall be erected and members
of each span marked distinctly.
1904.8 Welding
1904.8.1 All welding shall be done with the prior approval of the Engineer and the
workmanship shall conform to the specifications of IS:823 or other relevant Indian
Standards as appropriate.
When material thickness is 20 mm or more, special precautions like preheating

shall be taken as laid down in IS:823. Surfaces and edges to be welded shall be
smooth, uniform and free from fins, tears, cracks and other discontinuities.
Surface shall also be free from loose or thick scale, slag rust, moisture, oil and
other foreign materials. Surfaces within 50 mm of any weld location shall be free
from any paint or other material that may prevent proper welding or cause
objectionable fumes during welding.
The general welding procedures including particulars of the preparation of fusion

faces for metal arc welding shall be carried out in accordance with IS:9595.
The welding procedures for shop and site welds including edge preparation of
fusion faces shall be submitted in writing in accordance with Clause 22 of IS:9595

for the approval of the Engineer before commencing fabrication and shall also be
as per details shown on the drawings. Any deviation from above has to be
approved; by Engineer. Preparation of edges shall, wherever practicable, be
done by machine methods.
Machine flame cut edges shall be substantially as smooth and regular "as those
produced by edge planing and shall be left free of slag. Manual flame cutting
shall be pennitted by the Engineer only where machine cutting is not practicable.
Electrodes to be used for metal arc welding shall comply with relevant IS
specifications mentioned in IRC:24. Procedure test shall be carried out as per
IS:8613 to find out suitable wire-flux combination for welded Joint.
Assembly of parts for welding shall be in accordance with provisions of IS:9595.
The welded temporary attachment should be avoided as far as possible,

otherwise the method of making any temporary attachment shall be approved by
the Engineer. Any scars from temporary attachment shall be removed by cutting,
chipping and surface shall be finished smooth grinding to the satisfaction of the
Engineer.
Welding shall not be done when the air temperature is less than 10 degrees
Celsius. Welding shall not be done when the surfaces are moist, during periods
of strong winds or in snowy weather unless the work and the welding operators
are adequately protected.
1904.8.2 For welding of any particular type of joint, welders shall qualify to the satisfaction
of the Engineer in accordance with appropriate welders qualification test as
prescribed in any of the Indian Standards IS:817, IS:1966, IS:1393, IS:7307 (part
I), /5:7310 (Part I) and IS:7318 (part /) as relevant.
1904.8.3 In assembling and joining parts of a structure or of built up members, the

procedure and sequence of welding shall be such as to avoid distortion and
minimise shrinkage stress.
All requirements regarding pre-heating of parent material and interpass

temperature shall be in accordance with provision of IS:9595.
1904.8.4 Peening of weld shall be carried out wherever specified by the Engineer:
a) If specified, peening may be employed to be effective on each weld layer

except first

b)· The peening should be carried out after weld has cooled by light blows from a
power hammer using a round nose tool. Care shall be taken to prevent scaling or
flaking of weld and base metal from over peening.
1904.8.5 Where the Engineer has specified the butt welds are to be ground flush, the loss
of parent metal shall not be greater than that allowed for minor surface defects.
The ends of butt joints shall be welded so as to provide full throat thickness. This
may be done by use of extension pieces, cross runs or other means approved by
the Engineer. Extension pieces shall be removed after the joint has cooled and
the ends of the weld shall be finished smooth and flush with the faces of the
abutting parts.
The joints and welds listed below are prohibited type, which do not perform well
under cyclic loading.
a) Butt joints not fully welded throughout their cross-section
b) Groove welds made from one side only without any backing grip
c) Intermittent groove welds
d) Intermittent fillet welds
e) Bevel-grooves and J-grooves in butt joints for other than horizontal position.
f) Plug and slot welds
1904.8.6 The run-on and run-off plate extension shall be used providing full throat
thickness at the end of butt welded joints. These plates shall comply with the
following requirements.
(i) One pair of "run-on" and one pair of "run-off' plates prepared from same
thickness and profile as the parent metal shall be attached to start and finish of all
butt welds preferably by clamps.
(ii) When "run-on" and "run-off plates shall be removed by flame cutting,
it should be cut at more than 3 mm from parent metal and remaining metal shall
be removed by grinding or by any other method approved by the Engineer.

1904.8.7 Welding of stud shear connectors: The stud shear connectors shall be welded in
accordance with the manufacturer's instructions including preheating.
The stud and the surface to which studs are welded shall be free from scale,
moisture, rust and other foreign material. The stud base shall not be painted,
galvanised or cadmium plated prior to welding.
Welding shall not be carried out when temperature is below 10 degrees Celsius
or surface is wet or during periods of strong winds unless the work and the
welder is adequately protected.
The welds shall be visually free from cracks and shall be capable of developing at
least the nominal ultimate strength of studs.
The procedural trial for welding the stud shall be carried out when specified by
the Engineer.
1904.9 Tolerances
Tolerances in dimensions of components of fabricated structural steel work shall

be specified on the drawings and shall be subject to the approval of the Engineer
before fabrication. Unless specified, all parts of an assembly shall fit together
accurately within tolerances specified in Table 1900-2. A machined bearing
surface, where specified by the Engineer, shall be machined within a deviation of
0.25 mm for surfaces that can be inscribed within a square of side 0.5 m.
TABLE 1900-2 FABRICATION TOLERANCES
A. INDIVIDUAL COMPONENTS
1. Length
a) Member with both ends finished for contact bearing : 1mm
b) Individual components of members with end plate connection + 0mm
c) Other members
i) Upto and including 12 M : 2mm
ii) Over 12 M : 3.5mm
2. Width.
a) Width of built-up girders : 3.mm
b) Deviation in the width of members + 0mm
required to be inserted in other + 0mm

members
3. Depth
Deviation in the depths of solid + 3mm
web and open web girders -2mm
4. Straightness
a) Deviation from Straightness of columns L/3000 subject to a maximum of
15 mm where L is length of
member
i) In elevation +5mm
ii) In plan -0mm
5. Deviation of centre line of web from
centre line of flanges in built-up
members at contact surfaces 3mm
6. Deviation from flatness of plate of webs of 0.005 d to a
built-up members in a length equal to the maximum of 2mm
depth of the member where d is depth
of the member
7. Tilt offlange of plate girders 0.005 d to a maximum
a) At splices and stiffeners, at supports, of 2mm where b is width
at the top flanges of plate girders of the member
and at bearings
b) at other places of 4mm where b is width 0.005 d to a maximum
of the member
8. Deviation from squareness of flange to L/1000, where l is nominal
web of columns and box girders length of the diagonal
9. Deviation from squareness of fixed base D/500, where D is the
plate (not machined) to axis of column. distance from the column
This dimension shall be measured parallel axis to the point under

to the longitudinal axis of the column consideration on the base
at points where the outer surfaces of the plate
column sections make contact with the
base plate
10. Deviation from squareness of D/1000, where D is as
machined ends to axes of columns defined in 9 above
11. Deviation from squareness of machined D/1000, where D is as
ends to axes of beams or girder defined in 9 above
12. Ends of members abutting at joints 1/600 of depth of member
through cleats or end plates, subject to a maximum
permissible deviation from of 1.5mm
squareness of ends
1905 ERECTION
1905.1 General
The provisions of this item shall apply to erection of steel bridge superstructures
or main members of bridge superstructures, composed of steel, which span
between supports.
If the sub-structure and the superstructure are built under separate contracts, the
department will provide the substructure, constructed to correct lines, dimensions
and elevations properly finished and will establish the lines and the elevation
required for setting steel.
The Contractor shall erect the structural, steel, remove the temporary
construction, and do all the work required to complete the construction included
in the contract in accordance with the drawings and the specifications and to the
entire satisfaction of the Engineer.
1905.2 Organisation and Equipment
The Contractor shall submit erection plans prepared by the fabricator, showing a
method and procedure of erection, compatible with the details of fabrication.
A detailed scheme must be prepared showing stage-wise activities, with

complete-drawings and working phase-wise instructions. This should be based
on detailed stage-wise calculation and take into account specifications and

capacity of erection equipment machinery, tools, tackles to be used and

temporary working loads as per Codal provisions.
The scheme should be based on site conditions e.g. hydrology, rainfall, flood
timings and intensity, soil. and sub-soil conditions in the river bed and banks,
maximum water depth, temperature and climatic conditions and available working
space, etc.
The scheme should indicate precisely the type of temporary fasteners to be used
as also the minimum percentage of permanent fasteners to be fitted during the
stage erection. The working drawings should give clearly the temporary jigs,
fixtures, clamps, spacer supports, etc.
Unless otherwise provided in the contract, the contractor shall supply and erect
all necessary falsework and staging and shall supply all labour, tools, erection
plant and other materials necessary to carry out the work complete in all
respects.
The Contractor shall supply all rivets, bolts, nuts, washers, etc. required to
complete erection at site with an allowance for wastage, etc., of 12 1/2 per cent of
the net number of field rivets, bolts, washers required, or a minimum of five
number of each item.
Service bolts and nuts, ordinary platters, washers and drifts for use in the
erection of work shall be supplied at 60 per cent (45 per cent bolts and 15 per
cent drifts) of the number of field rivets per span in each size (this includes
wastage). A reduction in the quantities of service bolts, etc., may however, be
specified by the Engineer if more than one span of each type is ordered.
Prior to actual commencement of erection all equipment, machinery, tools,

tackles, ropes, etc. need to be tested to ensure their efficient working. Frequent
visual inspection is essential In vulnerable areas to detect displacements,
distress, drainages, etc.
Deflection and vibratory tests shall be conducted in respect of supporting

structures, launching truss as also the structure under erection and unusual
observations reviewed; looseness of fittings are to be noted.
For welded structures, welders' qualifications and skill are to be checked as per
standard norms. Non-destructive tests of joints as per designer's directives are to
be carried out.

Precision non-destructive testing instruments available in the market should be

used for noting various important parameters of the structures frequently and
systematic record is to be kept.
Safety requirements should conform to IS:7205, IS:7213 and IS:1269 as

applicable and should be a consideration of safety, economy and rapidity.
Erection work should start with complete resources mobilised as per latest
approved drawings and after a thorough survey of foundations and other related
structural work. In case of work of magnitude, maximum mechanisation is to be
adopted.
The structure should be divided into erectable modules as per the scheme. This
should be pre-assembled in a suitable yard/platform and its matching with
members of the adjacent module checked by trial assembly . before erection.
The structure shall be set out to the required lines and levels. The stocks and
masses are to be carefully preserved. The steelwork should be erected, adjusted
and completed in the required position to the specified line and levels with
sufficient drifts and bolts. Packing materials are to be available to maintain this
condition. Organised "Quality Surveillance" checks need to be exercised
frequently.
Before starting work, the Contractor shall obtain necessary approval of the
Engineer as to the method adopted for erection, the number and character of
tools and plants. The approval of the Engineer shall not relieve the Contractor of
his responsibility for the safety of his method or equipment or from carrying out
the work fully in accordance with the drawings and specifications.
During the progress of work, the Contractor shall have a competent Engineer or
foreman in charge of the work, who shall be adequately experienced in steel
erection and acceptable to the Engineer.
1905.3 Handling and Storing of Materials
Suitable area for storage of structures and components shall be located' near the
site of work. The access road should be free from water logging during the
working period andttie storage area should be on levelled and, firm ground.
The store should be provided with adequate handling equipments e.g road
mobile crane, gantries, derricks, chain pulley blocks, winch of capacity as
required. Stacking area should be planned and have racks, stands sleeper,
access tracks, etc., and properly lighted.

Storage should be planned to suit: erection work sequence and avoid damage or
distortion. Excessively rusted, bent or damaged steel shall be rejected. Methods
of storage and handling steel, whether fabricated or not shall be subject to the
approval of the Engineer.
Fabricated materials are to be stored with erection marks visible, such as not to
come into contact with earth surface or water and should be accessible to
handling equipment.
Small fitting hand tools are to be kept in containers in covered stores.
All materials, consumables, including raw steel or fabricated material shall be

stored specification-wise and size-wise above the ground upon platforms, skids
or other supports. It shall be kept free from dirt and other foreign matter and shall
be protected as far as possible from corrosion and distortion. The electrodes
shall be stored specification-wise and shall be kept in dry warm condition in
properly designed racks. The bolts, nuts, washers and other fasteners shall be
stored on racks above the ground with protective oil coath1g in gunny bags. The
paint shall be stored under cover in air-tight containers.
IS:7293 and IS:7969 dealing with handling of materials and equipments for safe
working should be followed. Safety nuts and bolts as directed are to be used
while working. The Contractor .shall be held responsible for loss or damage to
any material paid for by the Department while in his care or for any damage to
such material resulting from his work.
1905.4 Formwork
The formwork shall be properly designed, substantially built and maintained for all
anticipated loads. The Contractor, if required, shall submit plans for approval to
the Engineer. Approval of the plans, however, shall not relieve the Contractor of
his responsibility.
1905.5 Straightening Bent Material
The straightening of plates, angles and other shapes shall be done by methods
not likely to produce fracture or any injury. The metal shall not be heated unless
permitted by the Engineer for special cases, when the heating shall not be to a
temperature higher than that producing a dark "cherry red" colour, followed by as
slow cooling as possible. following the straightening of a bend or buckle the
surface shall be carefully investigated for evidence of fracture. Sharp kinks and
bends may be the cause for rejection of material.

1905.6 Assembling Steel
The parts shall be accurately assembled as shown on the drawings and match
marks shall be followed. The material shall be carefully handled so that no parts
will be bent, broken or otherwise damaged.
Hammering which will injure or distort the members shall not be done. Bearing
surface or surfaces to be in permanent contact shall be cleaned, before the
members are assembled. The truss spans shall be erected on blocking, so
placed as to give the proper camber. The blocking shall be left in place until the
tendon chord splices are fully riveted and all other truss
connections pinned and bolted. Rivets in splices of butt joints of compression

members and rivets in railings shall not be driven until the span has been swung.
All joint surface for bolted connections including bolts, nuts, washers shall be free
from scale, dirt, burrs, other foreign materials and defects that would prevent
solid seating of parts. The slope of surface of bolted parts in contact with bolt
head and nut shall not exceed 1 in 20, plane normal to bolt axis, otherwise
suitable tapered washer shall be used.
All fasteners shall have a washer under nut or bolt head whichever is turned in
tightening.
Any connection to be riveted or bolted shall be secured in dose contact with

service bolts or with a sufficient number of permanent bolts before the rivets are
driven or before the connections are finally bolted. Joints shall normally be made
by filling not less than 50 per cent of holes with service bolts and barrel drifts in
the ratio 4:1. The service bolts are to be fully tightened up as soon as the joint is
assembled. Connections to be made by dose tolerance or barrel bolts shall be
completed as soon as practicable after assembly.
Any connection to be site welded shall be securely held in position by approved

methods to ensure accurate alignment, camber and elevation before welding is
commenced.
The field riveting, welding, bolted and pin connection shall conform to the
requirements of Clause 1904 as appropriate.
The correction of minor misfits involving harmless amounts of reaming, cutting

and chipping will be considered a legitimate part of erection.

However, any error in the shop fabrication or deformation resulting from handling
and transportation which prevents proper assembling and fitting up of parts by
moderate use of drifts Of by a moderate amount of reaming and slight chipping or
cutting shall be reported immediately to the Engineer and his approval of the
method of correction obtained. The correction shall be made in the presence of
the Engineer.
1905.7 Field Inspection
1905.7.1 General
All materials, equipment and work of erection shall be subject to the inspection of
the Engineer who shall be provided with all facilities induding labour and tools
required at all reasonable times. Any work found defective is liable to be rejected.
1905.7.2 No protective treatment shall be applied to the work until the appropriate
inspection and testing has been carried out. The, stage inspection shall be
carried' out for an' operations so as to ensure the correctness of fabrication and
good quality. Girder dimensions and camber shall not be finally checked until all
welding and heating operations are completed and the member has cooled to a
uniform temperature.
1905.7.3 Testing of material: Structural steel shall be tested for mechanical and chemical
properties as per various IS codes as may be applicable and shall conform to
requirements specified in IS:226, IS:2062, IS:11587,IS:1977, IS:8500 and IS:961,
etc.
Rivets, bolts, nuts, washers, welding consumables, steel forging, casting and
stainless steel shall be tested for mechanical and chemical properties in the
appropriate IS Code.
Rolling and cutting tolerance shall be as per IS: 1852. The thickness tolerance
check measurements for the plate and rolled sections shall be taken at not less
than 15 mm from edge.
Laminations in plates shall be carried out by ultra-sonic testing or any other

specified methods.
Steel work shall be inspected for surface defects and exposed edge" laminations
during fabrication and blast cleaning. Significant edge laminations found shall be
reported to the Engineer for his decision.

Chipping, grinding, machining or ultrasonic testing shall be used to determine

depth of imperfection.
1905.7.4 Bolted connections: Bolts and bolted connection joints with high strength friction
grip bolts shall be inspected and tested according to IS:4000.
Rivets and riveted connection shall be inspected and tested for compliance of
codal requirements.
The firmness of joint shall be checked by 0.2 mm filler gauge, which shall not go
inside under the rivet head by more than 3 mm. There shall not be any gap
between members to be riveted.
Driven rivets shall be checked with rivet testing hammer. When struck sharply on
head with rivet testing hammer, rivet shall be free from movement and vibration.
All loose rivets and rivets with cracks, badly formed or deficient heads or with
heads which are eccentric with shanks, shall be cut out and replaced.
The alignment of plates at all bolted splice joints and welded butt jOints shall be
checked for compliance with codal requirements.
Testing of flame cut and sheared edges is to be done, where the hardness
criteria given in the code are adopted. Hardness testing shall be carried out on
six specimens.
1905.7.5 Welding and welding consumables: Welding procedure, welded connection and
testing shall be in compliance with codal requirements.
All facilities necessary for stage inspection during welding and on completion
shall be provided to the Engineer or their inspecting Authority by manufacturer.
Adequate means of identification either by identification mark or other record

shall be provided to enable each weld to be traced to the welder(s) by whom it
was carried out.
All metal arc welding shall be in compliance with IS:9595 provisions. The method
of inspection shall be in accordance with IS:822 and extent of inspection and
testing shall be in accordance with the relevant standards or in the absence of
such a standard, as agreed with the Engineer.
Procedure tests
The Destructive and Non-Destructive test of weld shall be carried out according
to IS:7307 (Part I).

Non-Destructive Testing of Welds
One or more of the following methods may be applied for inspection or testing of
weld:
(i) Visual Inspection : All welds shall be visually inspected, which should cover all
defects of weld such as size, porosity, crack in the weld or in the HAZ (Heat
Affected Zone) etc. Suitable magnifying glass may be used for visual inspection.
A weld shall be acceptable by visual inspection if it shows that:
a) The weld has no .cracks.
b) Through fusion exists between weld and base metal and between adjacent
layers of weld metal.
c) Weld profiles are in accordance with requisite clauses of IS:9595 or as agreed

with the Engineer.
d) The weld shall be of full cross section, except for the ends of intermittent fillet
welds outside their effective length.
e) When weld is transverse to the primary stress, undercut shall not be more than
0.25 mm deep in the part that is undercut and shall not be more than 0.8 mm
deep when the weld is parallel to the primary stress in the pan that is undercut.
f) The fillet weld in any single continuous weld shall be permitted to under run the
nominal fillet weld size specified by 1.6 mm without correction provided that
undersize portion of the weld does not exceed 10 per cent of the length of the
weld. On the web-to-flange welds oh girders, no under-run is permitted at the
ends for a length equal to twice the width of the flange.
g) The piping porosity in fillet welds shall not exceed one in each 100 mm of weld
length and the maximum diameter shall not exceed 2.4 mm, except for fillet welds
connecting stiffeners to web where the sum of diameters of piping porosity shall
not exceed 9.5 mm in any 25 mm length of weld and shall not exceed 19 mm in
any 300 mm length of weld.
h) The full penetration groove weld in butt joints transverse to the direction of
computed tensile stress shall have no piping porosity. For all other groove welds,
the piping porosity shall not exceed one in 100 mm of length and
(ii) Magnetic Particle and Radio-graphic Inspection: Welds that are subject to
radio-graphic or magnetic particle testing in addition to visual inspection shall
have no crack.

Magnetic particle lest shall be carried out for detection of crack and other
discontinuity in the weld according to IS:5334.
Radiographic test shall be carried out for detection of internal flaws in the weld
such as crack, piping porosity inclusion, lack of fusion, incomplete penetration,
etc. This test mat be carried out as per IS:1182 and IS:4853.
Acceptance Criteria: The weld shall be unacceptable if radiograph]c or magnetic

particle testing shows any of the type of discontinuities indicated in the code.
(iii) Ultrasonic Inspection : The Ultrasonic testing in addition to visual inspection

shall be carried out for detection of internal flaws in the weld such as cracks,
piping porosity inclusion, lack of fusion, incomplete penetration, etc. Acceptance
criteria shall be as per IS:4260 or any other relevant 15 Specification and as
agreed to by the Engineer.
iv) Liquid Penetration Inspection : The liquid penetrant test shall be carried out for
detection of surface defect in the weld, as per IS:3658, in addition to visual
inspection.
The non-destructive testing of following welds be carried out using one of the
method or methods described at (ii),(iii) and (iv) above, as may be agreed to by
the Engineer.
a) All transverse butt welds in tension flange
b) 10 per cent of the length of longitudinal and transverse butt welds in tension
flanges.
c) 5 per cent of the length of longitudinal and transverse butt welds in

compression flanges.
d) All transverse bun welds in webs adjacent to tension flanges as specified by

the Engineer.
The particular length of welds in webs to be tested shall be agreed with the
Engineer, in case of (b) or (c).
Where specified by the Engineer, bearing stiffeners or bearing diaphrag!f1s

adjacent to welds, flange plates adjacent to web/flange welds, plates at cruciform
welds, plates in box girder construction adjacent to corner welds or other details
shall be ultrasonically tested after fabrication.
Any lamination, lamellar tearing or other defect found shall be recorded and
reported to Engineer for his decision.

Testing of Welding for Cast Steel : The testing of weld for cast steel shall be
carried out as may be agreed to by the Engineer. Stud Shear Connectors : Stud
shear connectors shall be subjected to the following tests:
a) The fixing of studs after being welded in position shall be tested by striking the
side of the head of the stud with a 2 kg hammer to the satisfaction of the
Engineer.
b) The selected stud head stroked with 6 kg hammer shall be capable of lateral
displacement of approximately 0.25 the height of the stud from its original
position. The stud weld shall not show any sign of crack or lack of fusion.
The studs whose welds have failed the tests given in (al and (b) shall be
replaced.
1905.7.6 Inspection requirement: The fabricated member/component made out of rolled

and built-up section shall be checked for compliance of the tolerances given in
Table 1900-2. Inspection of member/components for compliance with tolerances,
and the check for deviations shall be made over the full length.
During checking, the inspection requirement shall be placed in such a manner

that local surface irregularities do not influence the results.
For plate, out-ot-plane deviation shall be checked at right angle to the surface
over the full area of plate.
The relative cross-girder or cross frame deviation shall be checked over the
middle third of length of the cross girder or frame between each pair of webs and
for cantilever at the end of member.
The web of rolled beam or channel section shall be checked for out-of plane
deviation in longitudinal direction equal to the depth of the section.
During inspection, the component/member shall not have any load or external
restraint.
Inspection Stages: The inspection to be carried out for compliance of tolerances

shall include but not be limited to the following stages: al For completed parts,
component members on completion of fabrication and before any subsequent
operation such as surface preparation, painting, transportation, erection.
b) For webs of plate and box girder, longitudinal compression flange stiffeners in
box girders and orthotropic decks and all web stiffeners at site joints, on
completion of site joint

c) For cross girders and frames, cantilevers in orthotropic decks and other parts
in which deviations have apparently increased on completion of site assembly.
Where, on checking member/component for the deviations in respect of out-of-

plane or out-of-straightness at right angles to the plate surface, and any other
instances, exceed tolerance, the maximum deviation shall be measured and
recorded. The recorded measurements shall be submitted to the Engineer who
will determine whether the component/member may be accepted without
rectification, with rectification or rejected.
1906 PAINTING
1906.1 General
Unless otherwise specified, all metal work shall be given approved shop coats as
well as field coats of painting. The item of work shall include preparation of metal
surfaces, application of protective covering and drying of the paint coatings and
supply of all tools, scaffolding, labour and materials necessary.
Coatings shall be applied only to dry surfaces and the coated surfaces shall not
be exposed to rain or frost before they are dry. The coatings shall be applied to
all surfaces excluding shear connectors and inner surfaces of fully sealed hollow
sections. Care shall be taken during coating of adjacent surfaces to build up
primer on the shear connectors.
1906.1.1 Types of paints
(i) Ordinary Paints
These include paints based on drying oils, alkyd resin, modified alkyd resin,
phenolic varnish epoxy, etc.
Alkyd resin paints for the protection of steel structures are based partly on natural
oils and partly on synthetic resins. These paints shall be used for steel structures
in atmospheres which are not too aggressive.
Oil based paints can be used for steel structures in cases where the surface
preparation cannot be ideal. Ordinary painting can generally be sub-divided into
two groups:
a) Primary Coats
This shall be applied immediately after the surface preparation and should have
the properties of adhesion, corrosion inhibition and imper-viousness to water and
air.

b) Finishing Coats
These are applied over the primary coat and should have the properties of
durability, abrasion resistance, aesthetic appearance and smooth finish.
(ii) Chemical Resistant Paints
The more highly corrosion resistant paints can be divided into two main groups:
a) One pack paints (ready for use)
b) Two pack paints (mixed before use)
The two pack paints shall be mixed together immediately before use since they
are workable thereafter only for a restricted period of time and dry up as a result
of a reaction between their components and yield hard tough films with resistance
to abrasion.
(iii) Vinyl Paints
These are based on polyvinyl resins such as polyvinyl-chloride (PVC) and

polyvinyl-acetate, etc.
Certain types of vinyl resin paints yield thick, relatively soft and rubber like
coatings with good chemical resistance. They can be repainted without difficulty.
(iv) Chlorinated Rubber Paints
These paints also have good chemical resistance. The main fields of applications
shall be in aggressive environments. In general, chlorinated rubber paints do not
have a high gloss.
(v) Bituminous Paints
As a paint vehide, bituminous is inferior, but because of the low price, this should
be applied in greater thickness (upto several millimetres) and may be suitable for
some situations. A significant advantage of bitumen paints is their impermeability
to ingress of water. However, bituminous paints do not withstand effectively
detrimental effects of oil.
(vi) Epoxy Paints
These resin paints have good adherence to a well prepared substrata. They are
mechanically strong and resistant to chemicals. A disadvantage of epoxy resin
paints is that it can rapidly become dull when exposed to strong sunlight. These
disadvantages do not, however, greatly influence their protective power.
(vii) Polyurethane Paints

The chemical and mechanical behaviour of polyurethane paint resembles those

of epoxy paint very much. However, polyurethane paint retains its gloss for a
longer period. Because of the high price of polyurethane paint, a combination of
the two viz., polyurethane and epoxy paints may sometimes be used.
(viii) Zinc Rich Paints
Instead of introducing an inhibitive pigment into paint, metallic zinc can be used
and such paints can provide cathodic protection to steel.
1906.1.2 Surfaces which are inaccessible for cleaning and painting after fabrication shall
be painted as specified before being assembled for riveting.
All rivets, bolts, nuts, washers etc., are to be thoroughly cleaned and dipped into
boiling linseed oil conforming to IS:77.
All machined surfaces are to be well coated with a mixture of white lead
conforming to IS:34 and Mutton Tallow conforming to IS:887.
For site paintings, the whole of the steel work shall be given the second cover
coat after final passing and after touching up the primer and cover coats, if
damaged in transit.
1906.1.3 Choice of painting system
The choice of suitable painting system is dependent on factors such as:
- Available application methods viz. brush, roller or spray

- Durability in a specific environment
- Availability of skilled manpower Cost I benefit etc.
It is therefore necessary to consult various manufacturers of paint and ascertain

the above aspects while deciding on the appropriate choice of painting system.
1906.1.4 Quality of paint: The paints which have been tested for the following qualities as
per the specifications given in the relevant IS codes should only be used:
- Weight Test (weight per 10 litre of paint thoroughly mixed)

- Drying time
- flexibility and Adhesion
- Consistency
- Dry thickness and rate of consumption

1906.1.5 Unless otherwise specified, all painting and protective coating work shall be done
in accordance with IS: 1477 (Part 1).
1906.2 Surface Preparation
Steel surface to be painted either at the fabricating shop or at the site of work
shall prepared in a thorough manner with a view to ensuring complete removal of
mill scale by one of the following processes as agreed to between the fabricator
and the Engineer:
a) Dry or wet grit I sand blasting.
b) Pickling which should be restricted to single plates, bars and sections.
c) Flame cleaning.
Primary coast shall be applied as soon a practicable after cleaning and in case of
flame cleaning, primary coat shall be applied while the metal is still warm.
All slag from welds shall be removed before painting. Surfaces shall be
maintained dry and free from dirt and oil. Work out of doors in frosty or humid
weather shall be avoided.
1906.3 Coatings
Prime coat to be used shall conform to the specification of primers approved by

the Engineer. Metal coatings shall be regarded as priming coatings. Primer shall
be applied to the blast cleaned surface before any deterioration of the surface is
visible. In any case, the surface shall receive one coat of primer within 4 hours of
abrasive blast cleaning.
All coats be compatible with each other. When metal coatings are used, the
undercoat and finishing coat shall preferably be from the same manufacturer.
Successive coats of paints shall be of different shades or colours and each shall
be allowed to dry thoroughly before the next is applied. Particular care shall be
taken with the priming and painting of edges, corners, welds and rivets. Typical
guidelines for epoxy based paints and the conventional painting system for bridge
girders as given below may be complied with:
a) Epoxy Based Painting
i) Surface preparation : Remove oil/grease by use of petroleum hydrocarbon

solution (lS:1745) and Grit blasting to near white metal surface.
ii) Paint system: 2 coats of epoxy zinc phosphate primer = 60 micron; Total 5
coats = 2000 micron

b) Conventional Painting System for areas where corrosion is not severe Priming
coat:
One heavy coat or ready mixed paint, red lead primer conforming to IS:102
Or
One coat of ready mixed chrome primer conforming to IS:104 followed by one
coat of ready mixed red oxide zinc chrome primer conforming to IS:2074.
Or
Two coats of zinc chromates red oxide primer conforming to IS:2074
Finishing Coats:
Two cover boats of red oxide paint conforming to IS:123 or any other approved
paint shall be applied over the primer coat. One coat shall be applied before the
fabricated steel work leaves the shop. After the steel work is erected at site, the
second coat shall be given after touching up the primer and the cover coats if
damaged in transit.
1:) Conventional Painting System for areas where corrosion is severe Priming
Coat:
Two coats of ready mixed red lead primer conforming to IS:102
Or
One coat of ready mixed zinc chrome primer conforming to IS:104 followed by
one coat of zinc chromate oxide primer to IS:2074.
Finishing Coats:
Two coats of aluminum paint conforming to IS: 2339 shall be applied over the
primer coat. One coat shall be applied before the fabricated steel work leaves the
shop. After the steel work is erected at site, the second coat shall be given after
touching up the primer and the cover coats if damaged in transit.
1906.4 Painting in the Shop
All fabricated steel shall be painted in the shops after inspection and acceptance
with at least one primary coat, unless the exposed surfaces are subsequently to
be cleaned at site or are metal coated. No primer shall be applied to galvanised
surfaces.
Shop contact surfaces, if specifically required to be painted, shall be brought

together while the paint is still wet.

Field contact surfaces and surface and surfaces to be in contact with cement
shall be painted with primer only. No paint shall be applied within 50 mm
designed location of field welds. Paint shall be completely dried before loading
and transporting to site.
Surface not in contact but inaccessible after shop assembly shall receive the fully
specified protective treatment before assembly.
Where surfaces are to be welded, the steel shall not be painted or metal coated
within a suitable distance from any edges to be welded if the specified paint or
metal coating would be harmful to welders or is expected to impair the quality of
site welds.
Exposed machined surfaces shall be adequately protected.
1906.5 Painting at site
Surfaces which will be inaccessible after site assembly shall receive the full
specified protective treatment before assembly.
Surfaces which will be in contact after site assembly shall receive a coat of paint
(in addition to any shop priming) and shall be brought together while the paint is
still wet.
Damaged or deteriorated paint surfaces shall be first made good with the same
type of coat as the shop coat.
Where steel has received a metal coating in the shop, this coating shall be
completed on site so as to be continuous over any welds, bolts and site rivets.
Specified protective treatment shall be completed after erection.
1906.6 Methods of Application
The methods of application of all paint coatings shall be in accordance with the
manufacturer's written recommendation and shall be as approved by the
Engineer. Spray painting may be permitted provided it will not cause
inconvenience to the public and is appropriate to the type of structure being
coated. Areas hard to gain access to for painting and areas shaded for spray
application shall be coated first by brushing.
Oil based red lead primers must be applied by brush only, taking care to work
into all corners and cervices.
The primer, intermediate and finishing coats shall be applied so as to provide

smooth coatings of uniform thickness. Wrinkled or blistered coatings or coatings

with pinholes, sags, lump or other blemishes shall not be accepted. Where the
Engineer so directs, the coating shall be removed abrasive blast cleaning and
replaced at the Contractor's expense.
1906.7 Guidelines of Specification for Protective Coating System in Different

Environments
Since the seriousness of the problem of corrosion depends upon atmospheric

conditions and these vary enormously, there is no single protective system or
method of application that is suitable for every situation.
However, as a guide broad recommendations are given in Table 1900-3 or

various types of coatings in various environmental conditions which should be
complied with, Approximate life to first maintenance is also indicated and can be
used as guide.
TABLE 1900-3: RECOMMENDATIONS FOR TYPES OF PROTECTIVE

COATINGS
System Environment
i) Wire brush to remove all loose rust Suitable for mild conditions where
and scale; 2 coats drying oil type appearance is of some importance is
primer; 1 under coat alkyd type paint; intended. This system may deteriorate
1 finishing coat alkyd type. Total dry to a marked extent if it is exposed to
film thickness = 150 µm moderate aggressive atmospheric
conditions for lengthy period.
Ii) Wire brush to remove all loose Similar to (i) but where appearance is
rust and scale; 2 coats drying oil not very important provides longer life
type primer; 2 under coats in mild conditions. Will provide upto 5
micaceous iron oxide (MXO) years life to first maintenance in
pigmented phenolic modified drying polluted inland environment.
oil. Total dry film thickness = 170 µm
iii) Blast clean the surface; 2 coats of Compared to (i) this would provide a
quick drying primer; undercoat alkyd longer life in mild conditions and could
type paint; 1 finishing coat alkyd be used in less mild situation e.g.
type. Total dry film thickness; 130- inland polluted, where maintenance
150 µm could easily be carried out at regular
intervals.
iv) Blast clean the surface; 2 coats of Suitable for general structural steel
drying type oil primer; 1 undercoat work exposed to ordinary polluted
micaceous iron oxide pigmented inland environments where
drying oil type paint. Total dry film appearance is not of primary
thickness 165 190 µm: importance.

v) Blast dean the surface; 2 coats of Suitable for structures in reasonably

metallic lead pigmented chlorinated aggressive conditions e.g. near the
rubber primer, 1 undercoat of high coat. Will provide long term protection
building chlorinated rubber, 1 than (iv) in non-coastal situations. Also
finishing coat of chlorinated rubber. suitable for aggressive interior
Total dry film thickness: 200 µm situations such as industrial areas.
vi) Blast clean the surface; 350 -450 Suitable for sea water splash zones or
µm thickness. Coal tar epoxy. for conditions of occurrence of frequent
salt sprays.
vii) Pickle; hot dip galvanised (Zinc). Suitable for steel work in reasonably
Total thickness: 85 µm mild conditions life of 15-20 years
before first maintenance could be
expected in many situations.
viii) Grit blast, hot dip galvanised Provides a longer life than (vii)
(Zinc). Total thickness = 140 µm because of thicker zinc coating.
ix) Grit blast; 1 coat of sprayed zinc / Expected to provide long term
aluminum followed by suitable protection approx. 15-20 years in
sealer. Total thickness = 150 µ!m aggressive atmosphere.
The material shall be tested in accordance with relevant IS specifications and

necessary test certificates shall be furnished. Additional tests, if required, shall be
got carried out by the Contractor at his own cost.
The fabrication, furnishing, erecting, painting of structural steel work shall be in

accordance with these specifications and shall be checked and accepted by the
Engineer.
The measurements of this item shall be in tonnes based on the net weight of
metal in the fabricated structure computed on the basis of nominal weight of
materials.
The weight of rolled and cast steel and cast iron shall be determined from the
dimensions shown on the drawings on the following basis:
- Rolled or cast steel 7.84x 103 kg/cu. cm.
- Cast Iron 7.21 x 103 kg/cu. cm
Weight of structural sections shall be nominal weight
Weight of castings shall be computed from the dimensions shown on the drawing
with an addition of 5 per cent for fillets and over-funs. Weight of weld fillets and
the weight of protective coatings shall not be included.

Weight of rivet heads shall be computed by taking the weight of 100 snap heads
as ,given in Table 1900-4.
When specially agreed upon, allowance for snap heads may be taken as a flat
percentage of the total weight. This percentage may be taken as 4 per cent or
modified by mutual agreement.
TABLE 1900-4 : WEIGHT OF RIVET HEADS
Dia of Rivet as manufactured Weight of 100 snap heads

mm Ka
12 1.3
14 2.1
16 3.4
18 4.45
20 6.1
22 8.1
24 10.5
27 15.0
30 20.5
33 27.2
The Contractor shall supply detailed calculation sheets for the weight of the metal
in the fabricated structure.
No additions shall be made for the weight of protective coating or weld fillets
Where computed weight form the basis for payment, the weight shall be
calculated for exact cut sizes of members used in the structure, deductions being
made for all cuts, except for rivet holes. Additions shall be made for the rivet
heads as mentioned above.
When specially agreed upon, the basis for payment may be the bridge weight
complete, according to specifications included in special provisions of the
Contract.
1909 RATE
The contract unit rate for the completed structural steel work shall include the
cost of all materials, labour, tools, plant and equipment required for fabrication,

connections, oiling, painting, temporary erection, inspection, tests and complete

final erection as shown on the drawings and as specified in these Specifications.

2000 BEARINGS

2001 DESCRIPTION
This work shall consist of furnishing and fixing bearings in position in accordance
with the details shown on the drawings, to the requirements of these
specifications or as directed by the Engineer.
2002 GENERAL
i) Bearing plates, bars, rockers, assemblies and other expansion or fixed devices
shall be constructed in accordance with the details shown on the drawings.
ii) The bearings may either be supplied directly to the Engineer by the
manufacturer to be installed by the Contractor or the Contractor is to supply and
install the bearings as part of the contract in the former case, the manufacturer
shall be associated with the installation of the bearings to the full satisfaction of
the Engineer, whereas in the latter case, the Contractor shall be solely
responsible for the satisfactory supply and installation of the bearing. In the
detailed description of the specification, a general reference shall be made to the
Contractor or manufacturer and the interpretation shall be as per terms of
contract
iii) The Contractor shall exercise the utmost care in setting and fixing all bearings
in their correct positions and ensuring that uniformity is obtained on all bearing
surfaces.
iv) Bearings shall be handled with care and stored under cover.
v) When bearing assemblies or plates are shown on the drawings to be placed

(not embedded) directly on concrete, the concrete bearing area shall be
constructed slightly above grade (not exceeding 12 nun) and shall be finished by
grinding.
vi) It shall be ensured that the bearings are set truly level and in exact position as
indicated on the drawings so as to have full and even bearing on the seats. Thin
mortar pads (not exceeding 12 mm) may even be made to meet with this
requirement
vii) It shall be ensured that the bottoms of girders to be received on the bearings
are plane at the locations of these bearings and care shall be taken that the
bearings are not displaced while placing the girders.

viii) MS. bearings sliding on M.S. Plates shall not be permitted. For sliding plate
bearings stainless, steel surface sliding on stainless steel plate with mild steel
matrix shall' be used. The other option shall be to provide PTFE surface sliding
on stainless steel.
ix) Some types of bearings which have been successfully used in various bridges
in India have been covered by these Specifications. For innovative types of
structures or in special cases, special types of bearings to suit the requirements
may have to be provided for which special specifications may be laid down by the
Engineer
2003 STEEL BEARINGS
2003.1 Materials
The material for steel bearings shall conform to the requirements of Section
1000. Some additional requirements for materials for steel bearings are indicated
below:
a) Railway axles (R 19) are also acceptable as forged steel for rollers.
b) For the purpose of checking the soundness of cast steel components, castings
shall be ultrasonically examined following procedures as per IS:7666 with
acceptance standard as per
IS:9565. The castings may also be checked by any other accepted method of
non-destructive testing as specified in IS: 1030. Quality level of castings shall be
level 3 as per IS:9565.
The grease for bearings shall conform to the requirements of IS:503 (Grade 4).
2003.2 Construction Operations
a) All work shall conform strictly to the drawings and shall be in accordance with
the provisions of this section. Care shall be taken to ensure that all parts of an
assembly fit accurately together. The workmanship shall satisfy all relevant
provisions laid down in Section 1900.
b) Knuckle pins, rolling surfaces of the rollers and bearing surface of the bearing
plates shall be machined and all bolt holes shall be drilled. The whole bearings
shall be fitted and finished as required for good quality machined work to the
satisfaction of the Engineer. However, in case of bearings which are to be
grouted or bedded on a suitable yielding material on any surface which is to be in

permanent contact with the grout or the yielding material may be left un
machined.
c) In prestressed concrete construction where launching of girders is employed,

in order to avoid slipping or jumping of rollers due to vibration or jolts, adequate
measures may be taken to ensure that the roller assembly is not disturbed. It is
normal practice to provide rocker bearings on the launching end and place the
beam on the rocker end slightly in advance of placing on the roller.
d) During concreting of girders, the bearings shall be held in position securely by

providing temporary connection between the top and bottom plates in case of
fixed bearings and between top plate, base plate and saddle plate in case of
roller-cum-rocker bearing or by any other suitable arrangement which prevents
the relative displacement of the components.
2003.3 Workmanship
al Fabrication shall be carried out by an organization experienced and qualified to

undertake precision engineering of this type and be approved by the Engineer.
b) Workmanship shall be of good quality, neatly finished and of good

appearance.
c) Casting shall be true to the forms and dimensions shown on the drawings and
shall be free from pouring faults, sponginess, cracks, blow holes and other
defects on position, affecting their appearance of strength. Warped or distorted
castings ill not be accepted. Exposed surfaces shall be smooth and dense.
d) All castings shall be cleaned by sand or shot blasting to remove sand or scale
and to present a clean uniform surface.
e) All irregularities, fins or risers shall be ground off flush with the adjacent
surface. Castings with visible cracks, blow holes or similar blemishes shall be
rejected if the imperfections are located in bearing surfaces or cannot be
remedied to the approval of the Engineer.
f) Imperfections which are not located in bearing surfaces shall be cleaned out,
filled with weld metal of the appropriate composition and ground flush.
g) All surfaces of major components like top plates, saddle plates, base plates,
rollers of the bearings shall be machined all over for correct alignment,
interchangeability, proper fitting, etc.

2003.4 Tolerances
Tolerances for its individual components or of the assembled bearings shall be as

shown on the drawings or subject to the approval of the Engineer. Unless
otherwise specified, the following tolerances shall be maintained:
Diameter of Rollers, Knuckle Pins and Bores
Tolerances on diameter of rollers and all convex surfaces shall conform to K7 of

IS:919.
Tolerances on diameter of all concave surfaces shall conform to D8 of IS:919.
Height of Bearings
Tolerances on height of any component casting shall not exceed +0.5mm. No

minus tolerance shall be allowed. The edges of all ribs shall be parallel
throughout their length.
Base Plate
Tolerances on length and width of the base plate shall not exceed +1.0 mm,
tolerance on the thickness of the plate shall not exceed +0.5 mm. No minus
tolerance shall be allowed. All rocking, rolling and sliding surfaces shall have a
machine smooth finish to 20 micron maximum mean deviation as per IS:3073.
Casting
No minus tolerance shall be allowed in the thickness of any part of the castings.
The edges of all ribs shall be parallel throughout their length.
2003.5 Installation of Steel Bearings
2003.5.1 General
a) Bearings shall be placed in the positions as shown on the drawings with all
bearing surfaces in full contact and to the tolerances as specified.
b) Roller and rocker bearings shall be placed so that their axles of rotations are
horizontal and normal to the direction of movement of the members they support.
Upper and lower bearing plates shall be set horizontal in both directions.
c) During installation the bearings shall be pre-set with respect to the bearing axis
to account for the movement due to the following:
i) Temperature variation between the average temperature prevailing at the time

of installation and the mean design temperature.

ii) Shrinkage, creep and elastic shortening.
d) For bridges in gradient, the bearing plates shall be placed in a horizontal

plane.
2003.5.2 Placing
a) On supporting structures, pockets shall b e provided to receive anchor bolts;

one side of the pocket shall project beyond the bearing plate.
The pocket shall be filled with mortar of mix 1:1 and the concrete bearing area
also shall be finished level by a thin and stiff mortar pad of mix 1:1 (the thickness
not exceeding 12 mm) just before placing of bearing assemblies or bottom plate
on the concrete seat
b) In case of precast girders a recess of 6 mm shall be provided on the underside

with a level finish for housing the bearing plate. A thin and stiff mortar pad of mix
1:1 with thickness not exceeding 3 mm shall be provided over the top plate
before lowering the precast beam in position in order to ensure full and even
pressure on the plate surface.
c) It shall be ensured that while placing the girders, the bearings are in their exact
positions as indicated on the approved drawing and not displaced therefrom.
d) All concrete surfaces to be in contact with the mortar shall be thoroughly

cleaned and kept saturated with water for a period not less than 24 hours before
placing mortar and operations are to be carried out when the surface
temperatures of the exposed bearings are the minimum practical.
e) No mortar that is more than 30 minutes old after completion of mixing, shall be
used.
f) After placing and finishing the mortar, the bearing shall be checked for position
and shims or other temporary supports removed and the mortar made good. If
the bearing has moved, it or the plate shall be lifted, the mortar removed and the
whole procedure repeated.
g) Exposed faces of the mortar shall be cured under damp Hessian for 7 days.
h) Placing of the bearing and mortar shall only be carried out in the presence of
the Engineer.

2003.5.3 Checking, cleaning and lubrication:
Before erection, each bearing shall be uncrated disassembled and checked. Any
damaged parts shall be made good for approval.
All bearings with sliding surfaces shall be cleaned and lightly lubricated with an
approved lubricant immediately before erection.
2003.5.4 Testing
i) The materials to be used in the bearings shall conform to the specifications laid
down in clause 2003.1.
ii) If required, a suitable number of complete bearings as specified by an

accepting authority shall be tested to 1.25 times the design load.
Recovery should be 100 per cent Contact surfaces shall be examined by

illumination source for any defects, ~racks, etc. Segmental rollers shall be tested
for design movements.
iii) For large lots (consisting of 12 sets or more) a quality control report shall be
submitted as detailed below:
a) Unless otherwise agreed upon by the Engineer and the manufacturer, the
latter shall furnish a complete report on the process of quality control. The
Engineer may appoint an authorised inspection agency for inspection purpose on
his behalf. Such an inspection agency shall also submit reports to the Engineer
regarding various tests performed on the bearing or certify the acceptance of the
bearings.
b) Test certificates of all raw materials shall be submitted. If manufacturer's test

certificates are not available for the raw materials, the bearings manufacturer
shall perform the necessary confirmatory tests as per relevant codes of practice
and shall furnish the test results.
c) A detailed quality control system inducing stage by stage inspection, starting

from raw materials upto the finished bearing shall be submitted by the bearing
manufacturer.
d) The Engineer shall reserve the right to witness such inspection at

manufacturer's works with or without prior permission of the manufacturer. For
this, the bearing manufacturer shall have in-plant testing facilities as far as
possible and practicable.

e) The bearing manufacturer shall maintain a list of consumption of raw material

for a period of at least previous one year.
f) Test certificates of bearings manufactured during preceding one year shall be

made available at the manufacturer's works.
g) In case the lot size of similar bearings exceeds 12 sets as per the direction of
the Engineer, one extra set of bearings for each 24 sets of bearings or part
thereof, shall be manufactured and the cost of such extra bearings shall be borne
by the user.
h) The Engineer shall select the extra bearing(s) at random and shall perform
various tests inducing destructive testing on it at his discretion, either at the
manufacturer's works or at any other approved test laboratory, notwithstanding
the test reports submitted.
i) In case there is a major discrepancy regarding material, the engineer shall

declare the whole lot of bearings as unacceptable.
j) In case minor defects in fabrication, like welding or machining, is found in the

test bearing before destructive testing and if the test bearing is found to be
acceptable after destructive testing, the minor defects in the test bearings shall
not be a bar to the acceptance of the entire lot.
k) The opinion of the Engineer in cases (i) and (j) above shall be binding on the
manufacturer.
2004 SPECIAL BEARINGS
2004.1 Spherical Bearing
This bearing only takes care of vertical load and horizontal force due to sliding
friction. The bearing will permit uniaxial translatory movement along longitudinal
axis of the bridge and rotation along all axes.
The bearing shall consist of the following parts:
2004.1.1 Bottom Plate
A bottom plate with concave surface is integrally cast on circular/ square plate.
The bottom plate is connected to the sub-structure by means of tight fitted anchor
bolts, which are embedded in concrete. The material of bottom plate shall be cast
steel.

Pure unfilled quality dimpled PTFE of specified thickness shall be provided on top
of concave surface of bottom plate in order to allow smooth rotation.
2004.1.2 Saddle Plate
A saddle plate with square/circular/rectangular top and convex surface at bottom

shall be placed in the concave surface of bottom plate. The radius of curvature of
the convex bottom of the saddle plate shall be slightly less than that of the
concave top surface of the bottom plate to ensure sufficient contact over a small
area: Rotation along all axes shall be permitted along the contact surface of the
saddle plate and the bottom plate. Pure unfilled quality dimpled PTFE sheet shall
be recessed to specified depth of recess over the top of saddle plate. Suitable
elastomeric seal shall be provided on the saddle plate to prevent ingress of dirt
and moisture. The material of saddle plate shall be cast steel.
2004.1.3 Top Plate
The top plate shall have stainless steel plate welded to its bottom which shall
slide over PTFE. The assembly shall be connected to the superstructure by tight
fitted anchor bolts. Translatory movements along longitudinal axis of bridge shall
be accommodated at the FILE/Stainless steel sliding surface. The material of top
plate shall be east steel.
2004.1.4 Guide Plate
Guide Plates shall be welded to saddle plate so as to permit only longitudinal

movement The material of guide plates should be cast steel.
2004.2 Pin Bearing
Pin bearing shall ensure fixity by arresting translatory movement. The pin bearing
shall not take any vertical load. It will take care of the longitudinal horizontal force
of the entire superstructure unit as well as transverse horizontal force developed
at the fixed end.
A pin bearing shall consist of a short height structural built-up column embedded
in pier cap and the protruding length inside soffit of deck shall have rocker plates
on all four sides, which permit rotation.
Pin bearing shall resist horizontal force from any direction and will permit rotation
but will not bear any vertical load. The material of pin bearing including rocker
plates shall be high tensile steel conforming to IS:961.

2004.3 In general the sliding spherical and pin bearing shall conform to 85:5400, Parts 9.1
and 9.2 and all relevant clauses of this specification. Bearings shall be
guaranteed for design loads and movements. The term bearing shall include the
entire assembly covering all the accessories required for operation, erection and
dismantling for replacement All bearings shall be of replaceable type. These
bearings should be based on their design to the specifications
mentioned/international specifications. The manufacturer should get their design
approved from appropriate authority and the manufacturer should be associated
with installation of bearings.
2004.4 Materials
All materials, particularly the following, shall be original, unused or non-re-cycled

conforming to relevant specifications:
- Cast Steel; Mild Steel. Stainless Steel shall conform to Cause

2003.1.
Copolymer Poly Tdtra Fluora Ethylene (PTFE) unfilled quality shall have required
properties as per BS:5400 and thickness shall be as specified.
- Anchor Bolts shall be as per relevant IS specifications.
2004.5 Seating of Pin Bearing
i) Backing plate with studs welded on the face opposite to the seating of
manufacture shall be delivered by the manufacturer.
ii) This backing plate shall be accurately positioned on the reinforcement grid of
the pedestal and levelled.
iii) Studs shall be tack welded/tied to the reinforcement to keep the backing plate
in proper location during casting.
iv) Depth of embedment of the backing plate in the concrete shall be as per
relevant drawing.
v) The round base of the pot (bottom) of the pin bearing assembly shall be
connected to the backing plates by anchor screws after concreting of pier
cap/pedestal.
vi) In order to ensure successful transfer of large horizontal forces to be resisted

by the Pin bearing, great care shall be taken in detailing the reinforcement in the
sub-structure and the super-structure adjacent to the studs in the backing plate.

2004.6 Acceptance Test on Spherical Bearings
1. All bearings shall be checked for overall dimensions
2. All bearings shall be load tested to 1.25 times design vertical load
3. A pair of bearings selected at random shall undergo testing in order to

determine coefficient of friction which shall be less than 0.05.
4. Two bearings selected at random shall be tested for permissible rotation.
2004.7 Acceptance Test on Pin Bearings
1. All bearings shall be checked for overall dimensions.
2. All bearings shall be load tested (if required, for design horizontal load only)
2005 ELASTOMERIC BEARINGS
The term "bearing" in this case refers to an elastomeric bearing consisting of one
or more internal layers of elastomer bonded to internal steel laminates by the
process of vulcanisation. The bearing shall cater for translation and/or rotation of
the superstructure by elastic deformation.
2005.1 Raw Material
Chloroprene (CR) only shall be used in the manufacture of bearing. Grades of

raw elastomer of proven use in elastomeric bearings, with low crystallization rates
and adequate shelf life (e.g. Neoprene WRT, Bayprene lib, Skyprene B-5 and
Denka S-40V) shall be used.
No reclaimed rubber or vulcanized wastes or natural rubber shall be used.
The raw elastomer content of the compound shall be lower than 60 per cent by its
weight The ash content shall not exceed 5 per cent (as per tests conducted in
accordance with ASTM D-297, sub-section 10).
EPDM and other similar candidate elastomers for bridge bearing use shall not be
permitted.
Properties
The elastomer shall conform to the properties specified in Table 2000.1
TABLE 2000-1. PROPERTIES OF ELASTOMER
Value of the
Test Method, IS specification
Propertiy Unit characteristic
reference
specified

Value of the
Test Method, IS specification
Propertiy Unit characteristic
reference
specified
Physical
1
Properties
1.1 Hardness IRHD IS:3400 Part II 60+5
Minimum Tensile
1.2 MPa IS:3400 Part I 17
Strength
Minimum
1.3 Elongation at Percent IS:3400 Part II 400
break
IS:3400 Part X
Maximum Duration Temperature
2 Percent 35
Compression set (h) (deg C)
+0 to 24.2 100±1
CR
IS:3400 Part IV
Accelerated Duration Temperature
3
Ageing (h) (deg C)
CR 70 100±1 +15
Max change in
3.1 IRHD -15
hardness
maximum change
3.2 Percent
in tensile strength
maximum strength
3.3 Percent -40
in elongation
Shear modulus of the elastomer bearing shall neither be less than 0.80 MPa nor
greater than 1.20 MPa.
The adhesion strength of elastomer to steel plates determined according to

IS:3400 (Part XIV) method A shall not be less than 7 kN/m.
For elastomeric bearings (CR) used in adverse climatic conditions the following
ozone resistance test shall be satisfied:
The ozone resistance of elastomer shall be proved satisfactory when assessed

by test according to IS:3400 (Part XX)The strain, temperature, duration and
ozone concentration of the test shall be 20 per cent, 40 ± 1 degree Celsius, 96 h
and 50 pphm volume respectively

No cracking detected by visual observation at the end of the test shall be

considered satisfactory. No specific tests for assessment of low temperature
resistance- may be deemed necessary.
NOTE: For use of elastomer in extreme cold climates, the Engineer may specify
special grade of low temperature resistant elastomer in conformity with operating
ambient temperature conditions. The specifications of such special grade
elastomer including the tests for low temperature resistance shall be mutually
agreed to by the Engineer and the producer supplier and are outside the purview
of these specifications.
Laminates of mild steel conforming to IS:226 shall only be permitted to be used.

Use of any other material like fibre glass or similar fabric as laminates shall not
be permitted.
The manufacturers of elastomeric bearings shall satisfy the Engineer that they
have in-house facilities for testing the elastomer for carrying out the following
tests in accordance with the relevant provisions of ASTM D- 297.
a) Identification of polymers to confirm the usage of

Chloroprene (Appendix X-2)
b) Ash content test to determine the percentage

(sub-section 34)
c) Specific gravity test (sub-section 15)
d) Polymer content test (sub-section 10)
The Engineer shall invariably get the test (a) performed within his presence or in
the presence of his authorised representative to satisfy the requirement In case
of any disputes regarding interpretation of results the Engineer may carry out test
as per ASTM 5-3452-78 (Chrotography test) at the manufacturer's cost in a
recognised test house.
The elastomer specimen to conduct the test shall be obtained from the bearings
selected at random for destructive test. Remaining part of the test bearing shall
be preserved by the Engineer for any test to be done in future, if required.
2005.2 Fabrication
Bearing with steel laminates shall be cast as a single unit in a mould and
vulcanised under heat and pressure.

Casting of elements in separate units and subsequent bonding shall not be

permitted, nor shall cutting from large size cast be permitted. Bearings of similar
size to be used in particular bridge project shall be produced by identical process
and in one lot as far as practicable. Phased production may only be resorted to
when the total number of bearings is large enough.
The moulds used shall have standard surface finish adequate to produce
bearings free from any surface blemishes.
Steel plates for laminates shall be sand blasted, dean of all mill scales and shall
be free form all contaminants prior to bonding vulcanisation.
Rusted plates with pitting shall not be used. All edges of plates shall be rounded.
Spacers used in mould to ensure cover and location of laminates shall be of

maximum size and number practicable. Any hole at surface or in edge cover
shall be filled in subsequently.
Care shall be taken to ensure uniform vulcanising conditions and homogeneity of

elastomer through the surface and body of bearings.
The bearings shall be fabricated with the tolerances specified in Table 2000-2.
TABLE :2000-2 TOLERANCES
ITEMS TOLERANCES
1 Overall plan dimensions -0,4-6 mm
2 Total bearing thickness -0, + 5 mm
3 Parallelism
Of top surface of bearing with respect to

a) 1 in 200
the bottom surface as datum
b) Of one side surface with respect to the 1 in 100

other as datum
4a Thickness of individual internal layer of ± 20 percent (max. of
elastomer 2mm)
b) Thickness of individual outer layer -0, + 1mm
5a Plan dimensions of laminates -3mm, +0
b) Thickness of laminates ± 10 percent

Parallelism of laminate with respect to

c) 1 in 100
bearing base as datum
The vulcanising equipment/press shall be such that between the plattens of press
the pressure and temperature are uniform and capable of being maintained at
constant values as required for effecting a uniform vulcanisation of the bearing.
The moulding dies utilised for manufacturing the bearings shall be so set inside
the platten of the press so that the pressure developed during vulcanisation of the
product is evenly distributed and the thickness
maintained at all places are within acceptable tolerance limits taking into
consideration the shrinkage allowance of vulcanizate.
The raw compound which has been introduced inside the metal dies for
vulcanisation shall be accurately weighed each time and it must be ensured that
sufficient quantity has been put inside the die for proper flow of material at every
place so that a homogeneous and compact bearing is produced without any sign
of sponginess or deficiency of material at any place.
Before any vulcanizate of any batch of production is used for producing

vulcanised bearings, test pieces in the form of standard slab and buttons shall be
prepared in accordance with prescribed standards and salient properties tested
and recorded regularly against each batch of production to monitor the quality of
the products.
2005.3 Acceptance Specifications
The manufacturer shall have all the test facilities required for the process and
acceptance control tests installed at his plant to the complete satisfaction of the
Engineer. The test facilities and their operation shall be open to inspection by the
Engineer on demand.
All acceptance and process control tests shall be conducted at the

manufacturer's plant. Cost of all materials, equipment and labour shall be borne
by the manufacturer unless otherwise specified or specially agreed to between
the manufacture and Engineer.
Acceptance testing shall be commenced with the prior submittal of testing

programme by the manufacturer to the Engineer and after obtaining his approval.
Any acceptance testing delayed beyond 180 days of production shall require
special approval of the Engineer and modified acceptance specification, if
deemed necessary by him.

All acceptance testing shall be conducted by the Inspector with aid of the
personnel having adequate expertise and experience in rubber testing provided
by the manufacturer, working under the supervision of the Inspector and to his
complete satisfaction.
Lot by lot inspection and acceptance shall be made.
2005.3.1 Acceptance lot:
A lot under acceptance shall comprise all bearings, including the pair of extra test
bearings where applicable of equal or near equal size produced under identical
conditions of manufacture to be supplied for a particular project.
The size and composition of acceptance lot shall be got approved the Engineer.
For the purpose of grading levels of acceptance, testing lots shall be classified as
follows:
i) A lot size of 24 or larger number of bearings shall be defined as a large lot
ii) A lot size of less than 24 bearings shall be defined as a small lot When the
number of bearings of equal or near equal size for a single bridge project is large
and phased production and acceptance is permitted, the number of bearings
supplied in any single phase of supply shall comprise a lot under acceptance.
When such phased supply is made, each such lot shall be considered as~ large
lot for the purpose of acceptance testing.
2005.3.2 Levels of acceptance inspection:
The level of acceptance testing shall generally be graded into the following two
levels depending on lot size:
level 1 acceptance testing
Level 2 acceptance testing
Acceptance testing level 1 is a higher level inspection and shall be applicable to

large lots only, unless otherwise specified. This shall involve manufacture of two
extra bearings for each lot to be used as test bearing and eventually consumed in
destructive testing.
Acceptance testing level 2 shall be applicable to small lots only, (i.e. less than 24
lots) for which one extra bearing shall be manufactured. Out of the lot one
bearing shall be selected at random for carrying out material tests. This bearing
shall be excluded from the lot accepted.

Acceptance inspection level 1 may be specified at the sole discretion of the

engineer taking into account the special importance of bridge project for small
lots also under the purview of special acceptance inspection. The cost of extra
bearings, in such cases shall be borne by the user, while the cost of all other
materials, equipment and testing shall be borne by the manufacturer.
2005.3.3 Testing:
Acceptance testing shall comprise general inspection, test on specially moulded

test pieces and test on complete bearings or sections for measurement of various
quality characteristics detailed below:
2005.3.3.1 Acceptance testing level 1
General Inspection
1. All bearings of the lot shall be visually inspected for any defects in surface
finish, shape or any other discernible superficial defects.
2. All bearing of the lot shall be checked for tolerances specified in Table 2000-2.
3. All bearings of the lot shall be subjected to axial load to correspond to om (i.e,
average compressive stress) = 15 Mpa applied in steps and held constant while
visual examination is made to check for discernible defects like:
a) Misalignment of reinforcing plates
b) Poor bond at laminate I steel interface
c) Variation in thickness of elastomer layers.
d) Any surface defects
e) Low stiffness
Deflection under loads between om = 5 Mpa and om = 15 MPa shall be

measured and recorded for all bearings with sufficient accurancy (± 5 percent)
,variation in stiffness of any individual bearing from the mean of the measured
values for all such bearings of the lot shall not be larger than 20 per cent (of the
mean value).
Tests on specially moulded test pieces
1. Test pieces shall be moulded by the manufacturer with identical compound

and under identical vulcanising conditions as used in the manufacture of the
bearings of the acceptance, lot. The process shall be open to inspection by the
Engineer.

2. Test pieces offered for inspection shall be identified by suitable markings and
duly certified by the manufacturer.
3. The quality characteristics to be tested are listed below. The specification

references in parenthesis shall define the corresponding specification for test
pieces, test method and criterion for acceptance.
Composition (see Not 1 below)
Hardness (Table 2000-1,1.1)
Tensile strength (Table 2000-1,1.2)
Elongation at Break (Table 2000-1,1.3)
Compression Set (Table 2000-1,2)
Accelerated Ageing (Table 2000-1,3)
Adhesion Strength (Clause 2005.1)
Ozone Resistance (see Note 2 below)
Note 1.
For acceptance testing the properties enumerated in Clause 2005.1 and specific
gravity of elastomer of test pieces from test bearing shall be compared with those
for corresponding specially moulded test pieces furnished by the manufacturer.
The following variations shall be deemed maximum acceptable:
Specific Gravity ;. 0.2
Ash Content ± 0.5 per cent
Hardness (Table 2000-1 , 1.1)
Tensile strength (Table 2000-1 , 1.2)
Elongation at Break (Table 2000-1 ,1.3)
Compression Set (Table 2000-1, 2)
Accelerated Ageing (Table 2000-1, 3)
Adhesion Strength (Clause 2005.1)
Note 2.
Ozone resistance test can be waived by the Engineer for bearings of CR when
satisfactory results of ozone resistance tests on similar grade of elastomer may

be available from process control records or development test data furnished by

the manufacturer.
Where such process control data are not available or the frequency of testing not
deemed adequate, ozone resistance test shall be mandatory for acceptance of
bearings of CR.
However, such tests may not be insisted for bearings not located under adverse
conditions of exposure and where the test on accelerated ageing could be
considered as adequate.
Process and acceptance control tests for ozone resistance by an independent

testing agency shall be acceptable.
Tests on Complete Bearings or Sections
1. Two bearings shall be selected at random from the lot as test bearings. These
bearings shall be excluded from the lot accepted.
2. The following tests shall be conducted on test bearings:
Test for determination of shear modulus
Test for determination of elastic modulus
Test for determination of shear modulus (short term loading)
Test for determination of adhesion strength
Test for determination of ultimate compressive strength
The test specifications and acceptance criteria shall conform to those given in
Appendix 2 of IRC:83 (Part II).
2005.3.3.2. Acceptance testing level 2
General Inspection. This shall conform to the provision in Clause
2005.3.3.1 in all respects.
Test on specially moulded test pieces. This shall conform to the provisions in
Clause 2005.3.3.1 in all respects.
Test on complete bearings. Test for determination of shear modulus shall be

conducted using two bearings of the lot selected at random and conforming to
relevant provisions of Clause 2005.3.3.1. These bearings shall however be part
of the lot accepted. The remaining tests stipulated in aforesaid clause shall be

carried out on ali bearings selected at random which shall be excluded from the
lot accepted.
2005.3.4 Special acceptance inspection: Special acceptance inspection may comprise the
following:
1. Acceptance testing by an independent external agency with separate or

supplemental test facilities provided by it say the D.G.S.D. Govt. of Maharashtra
2. Acceptance testing on test pieces prepared from the surface or body of the test
bearings instead of specially moulded test pieces.
3. Acceptance tests not covered by these specifications but according to the

specifications laid down by the Engineer.
Special acceptance inspection may be specified under the following conditions:
a) Special contract agreement
b) Unsatisfactory evidence of process or acceptance control
2005.3.5 Inspection certificate: A lot under inspection shall be accepted by the Inspector
and so certified, when no defect is found with respect to any of the quality
characteristics tested on samples drawn from the lot according to specifications
laid down in Clause 2005.3.3 covering general inspection tests on specially
moulded test pieces and on complete bearings.
In case of any bearing with defect, the lot shall be rejected by the Inspector and
so certified.
In case any bearing is found to be defective with respect to any quality

characteristic, discerned by general inspection tests specified in Clauses
2005.3.3.1 and 2005.3.3.2, tests on specially moulded test pieces and eomplete
bearings as applicable according to Clauses 2005.3.3.1 and 2005.3.3.2 shall
nevertheless be completed. If the said lot, rejected by general inspection,
satisfies the acceptance criteria in respect of these other tests, the lot and
individual bearings found defective shall be clearly identified in the inspection
certificate.
The manufacturer shall obtain from the inspector, authorised by the Engineer,
immediately on completion of his inspection, an inspection certificate which shall
include the details of a lot or lots accepted/rejected by him and records of all test
measurements.

2005.3.6 Quality control certificate: The manufacturer shall certify for each lot of bearing
under acceptance:
That an adequate system of continuous quality control was operated in his plant.
That the entire process remained in control during the production of the lot of
bearings under acceptance as verified from the quality control records/charts
which shall be open to inspection of Engineer/Inspector on demand.
A certified copy of results of process control testing done on samples of

elastomer used in the production of the lot shall be appended and shall include at
least the following information:
Composition of compound - raw elastomer and ash content, the grade of raw
elastomer used (including name, source, age on shelf), test results of hardness,
tensile strength, elongation at break, compression set, accelerated ageing, etc.
A higher level certification of the process quality control shall be called for at the
sole discretion of the Engineer in special cases e.g. where adequate inspection of
bearings similar to those comprising the lot (under inspection produced in the
same plant is not available with the Engineer or in case of any evidence of
process or acceptance control being deemed unsatisfactory.
The higher level certification shall comprise submittal of a complete quality

control report as given in Appendix 3 of IRC83 (Part III supplementing the quality
control certificate.
2005.3.7 Acceptance: The manufacturer shall furnish the following to Engineer for the
acceptance judgement:
1. Quality control certificate as laid down in Clause 2005.3.6.
2. Inspection certificate as laid down in Clause 2005.3.5.
The manufacturer shall furnish any supplementary information on the system of

quality control and/or process and acceptance control testing as may be deemed
necessary by the Engineer.
In case of any evidence of process or acceptance control testing being deemed

unsatisfactory by him, Engineer at his sole discretion may call for a special
acceptance of the lot according to specifications laid down by him, without any
prejudice to his right to reject the lot. The entire cost of such supplementary
inspection shall be borne by the manufacturer.

The Engineer shall be the sole authority for acceptance of a lot on scrutiny of the
certificates along with any supplementary evidence and complete satisfaction
therewith.
In case of rejection of a lot, the Engineer shall reserve the right to call for special
acceptance inspection for the succeeding lots offered for inspection, according to
the specifications laid down by him. The entire cost of such tightened inspection
shall be borne by the manufacturer.
2005.4 Certification and Marking
Bearings shall be transported to bridge site after final acceptance by Engineer

and shall be accompanied by an authenticated copy of the certificate to that
effect.
An information card giving the following details for the bearings, duly certified by
the manufacturer shall also be appended:
Name of manufacturer
Date of manufacture .
Elastomer grade used
Bearing dimensions
Production batch no.
Acceptance lot no.
Date of testing
Specific bridge location, if any
Explanation of markings used on the bearing
All bearings shall have suitable index markings identifying the information.
The markings shall be made in indelible ink or flexible paint and if practicable
should be visible after installation. The top of the bearing and direction of
installation shall be indicated.
2005.5 Storage and Handling
Each elastomeric bearing shall be dearly labelled or marked. The bearing shall
be wrapped in a cover. They shall be packed in timber crates with suitable
arrangement to prevent movement and to protect comers and edges.

Care shall be taken to avoid mechanical damage, contamination with oil, grease
and dirt, undue exposure to sunlight and weather to the bearings during transport
and handling prior to and during installation.
2005.6 Installation
Installation of multiple bearings one behind the other on a single line of support
shall be of identical dimensions.
Bearings must be placed between true horizontal surfaces (maximum tolerance

0.2 per cent perpendicular to the load) and at true plan position of their control
b'nes marked on receiving surfaces (maximum tolerance ± 3 mm).
Concrete surfaces shall be free from local irregularities (maximum tolerance ± 1

mm in height).
Design shall be checked for the actual inclination in seating if larger inaccuracies
than those specified are permitted.
For cast-in-place concrete construction of superstructure, where bearings are

installed prior to its concreting, the forms around the bearings shall be soft
enough for easy removal. Forms shall also fit the bearings snugly and prevent
any leakage of mortar grout Any mortar contaminating the bearings during
concreting shall be completely removed before setting.
For precast concrete or steel superstructure elements, fixing of bearing to them

may be done by application of epoxy resin adhesive to interference after
specified surface preparation. The specifications for adhesive material,
workmanship and control shall be approved by the Engineer. Care shall be taken
to guard against faulty application and consequent behaviour of the adhesive
layer as a lubricant. The bonding by the adhesive shall be deemed effective only
as a device for installation and shall not be deemed to secure bearings against
displacement for the purpose of design.
As a measure of ample safety against accidental displacement, the bearings shall

be placed in a recess as shown in Fig. 9 of IRC: 83 (Part ID. 2005.7. Seating of
Elastomeric Bearings on a Non-Horizontal Plane Installation of elastomeric
bearings on a Non-Horizontal Plane shall be -:as follows:
i) Elastomeric bearings shall be delivered with MS backing plate fastened to the

bearing from the manufacturer.

ii) Template of 6 mm M.S. plate and of size same as bearing holding base plate
with matching holes for the anchor screws shall be used. Anchors shall be fitted
to the templates with the anchor screws but with MS washers in place of
elastomer washers. The above template assembly shall be fitted in the formwork
at its proper location and in a vertical plane.
iii) After casting of the pedestal and removal of the form work, the template is to
be removed.
A. Installation with face plate and without template in-situ casting
i) The sub-assembly of elastomeric bearing with the MS backing plate shall be

fitted to the embedded anchors with anchor screws and elastomeric washers
replacing the steel washer.
ii) A clearance is required between the stainless steel face of the elastomeric
bearing and that of the vertical face of the face plate with stainless steel top
installed on the projection below the soffit. This shall be achieved by inserting
removable steel sheeting of thickness as per the drawing, during preparation of
the formwork before casting of the superstructure.
iii) The face plate with stainless steel top and pack plate shall be assembled with
the anchors with elastomeric washers and anchor screws. The assembly shall be
fitted in the formwork at its proper location and in a vertical plane. The removable
steel shims shall be removed at an appropriate time after the casting of the
super-structure.
B. Installation with face plate and with template in-situ casting
i) Template of 6 mm MS plate and of size same as face plate with stainless steel
top and matching holes for the anchor screws shall be used Anchors shall be
fitted to the templates with the anchor screws but with MS washers in place of
elastomer washers.
Separate screws may be used in case of inconvenience of in the length of origini

anchor screws. The above template assembly shall be fitted in the form work for
the super-structure at its proper location and in a vertical plane,
ii) After removal of the superstructure form work, the template shall be removed.
iii) The face plate with the required thickness of pack plate shall be loosely fitted
to the anchors embedded in the projection below the superstructure, with
elastomer washers and anchor screws.

iv) The sub-assembly of elastomeric bearing with the MS backing plate shall be
fitted to the embedded anchors in the pedestal with anchor screws and
elastomeric washers replacing the steel washer this time.
v) The required clearance between the stainless steel face of the elastomeric
bearing and that of the vertical face plate installed on the projection below the
soffit shall be checked. After adjustment of the required working clearance the
small gap between the vertical face of the projection below the soffit and the back
of the face plate (with pack plates, if any) shall be grouted with epoxy grout
2006 POT BEARINGS
2006.1 General
2006.1.1 Pot type bearings shall consist of a metal piston supported by a disc or
unreinforced elastomer confined within a metal cylinder to take care of rotation.
Horizontal movement, if required, shall with a system of sealing rings be provided
by sliding surfaces of PTFE pads sliding against stainless steel mating surfaces.
The pot bearings shall consist of cast steel assemblies or fabricated structural
steel assemblies.
2006.1.2 Provisions of IRC-83 (Part I) shall be applicable for all metallic elements.
Provisions of IRC: 83 (Part II) shall be applicable for all elastomer elements.
When any items are not covered by IRC:83 (Parts I and H), the same shall be as
per guidelines given hereunder and BS:5400 (Sections 9.1 and 9.2), except that
no natural rubber shall be permitted. If there is any conflict between BS on the
one hand and IRC on the other, the provisions of IRC will be guiding.
2006.1.3 Combination bearings using any judicious combination and sliding element shall
be permitted. As for example:
Rotation Sliding
Name Generally for
Element Element
Pot Pot None Vertical Load
Elastomer Elastomer None* Horizontal Buffer
Vertical Load and
Pot PTFE Pot PTFE- SS**
Horizontal Load
Spherical
Spherical Vertical load and
Knuckle PTFE- SS**
Knuckle Horizontal load
PTFE
Elastomer
Elastomer PTFE- SS** Transverse Guide
PTFE

Rotation Sliding
Name Generally for
Element Element
Elastomer Transverse
Elastomer SS**
SS** Guide
* Elastomer shall permit movement
** Stainless Steel
For special and innovadve bridges, new combinations beyond what is shown may
be required. The same may be used after approval by the Engineer
2006.2 Fabrication
i) The surface mating with the PTFE in the sliding pair shall be corrosion resistant
stainless steel. Normally, the stainless steel shall form the upper component. The
stainless steel shall overlap the PTFE after full movement on all side*. If stainless
steel sheet is used, it should be bonded by continuous welding along the edges.
Adhesive or any other bonding can be approved by the Engineer. The surface
shall be prepared by thorough cleaning to remove grease, dust or any other
foreign substance.
ii) PTFE modular sheets of the sliding pair shall be located by confinement
assisted by bonding. Confined PTFE shall be recessed into the metal backing
plate. The shoulders of the recess shall be sharp and square to restrict the flow of
PTFE.
iii) The thickness of the PTFE shall not be less than 4.5 mm with projection above
the recess not exceeding 2.0 mm. When the piston is subjected to tilting, the seal
must slide along the wall and alter its shape according to the angle of tilt At the
same time, it must be sufficiently rigid to bridge the gap between the piston and
the wall of the pot.
However, the percentage of plan area .of the lubrication cavities to the gross area
shall not exceed 25 per cent. The depth of the cavity shall not exceed 2.0 mm.
iv) The diameter to thickness ratio of the confined elastomer shall not exceed 15.
The surface of the confined elastomer shall be smooth.
v) A seal shall be provided to prevent extrusion of the confined elastomer

between the piston and the pot wall. The seal should stay functional under the
loads and rotations acting on it. Additional seal shall be provided to prevent entry
of dust into the for .pot. Sealing ring for pot bearing shall be fabricated from
stainless steel. When the piston is subjected to the seal must slide the wall and

alter its shape according to the angle of tilt. At the same time, it must be
sufficiently rigid to bridge the gap between the piston and the wall of the pot
vi) The hardness of the piston and pot wall at their contact region shall be
minimum 350 BHN to reduce wear. The surface finish of the pot base in contact
with the confuted elastomer shall be very smooth.
iv) All bearings shall be installed with anchor and anchor screws or some similar
device such that while replacing, the bearings can be removed with minimum
lifting of the superstructure.
viii) The external surfaces of the assemblies shall be completely cleaned by sand
blasting. After sand blasting, dust shall be removed from the surface using dean
and dry compressed air or a clean brush after which suitable coating shall be
applied.
Ix) Pot bearings Including all parts as shown on the drawings shall be fully shop
assembled at the manufacturer's works to ensure proper fitting of all parts.
2006.3 Materials
a) Steel
i) Structural steel shall conform to IS:226 and IS:2062, as applicable.
ii) Cast steel shall conform to Gr 2BO-S20W of IS: 1030. 0.3 to 0.5 per cent
copper may be added to increase the corrosion resistance properties.
iii) Stainless steel shall conform to AISI:304 or XO4Crl8NilO of IS:6911 for

ordinary applications. For applications with adverse/corrosive environment, the
stainless steel shall conform to AISI:316L or 02Crl7Nil2Mo2 of IS:6911.
b) PTFE
PTFE (poly letra fluore ethylene) shall be of unfilled pure virgin quality. It shall be
free sintered. The mechanical properties of unfilled PTFE shall comply with
Grade A of 65:3784.
c) Elastomer
The confined elastomer inside pot will have the following properties:
a) Hardness IRHD 13:3400 (Part II) 50 + 5
b) Min tensile strength….. MPa IS:3400 (Part I) 15.5
c) Min elongation at break) shall be as per Table 2000-1

Max compression set and) "Properties of Elastomer"
Accelerated ageing)
For other details, refer to Clause 2005.1.
2006.4 Workmanship
2006.4.1 Welding
All welding shall conform to IS:9595 with electrodes of suitable grade as per
IS:814. Preheating and post weld stress relieving shall be done as per IS:9595.
2006.4.2 Cast steel assemblies: Cast steel for pot bearing assemblies shall conform to
requirements of relevant IS. Castings shall be true to the forms and dimensions
shown on the drawings, and shall be free from pouring faults, sponginess, cracks,
blow holes and other defects affecting their appearance or their strength. Warped
or distorted castings shall not be accepted. Exposed surfaces shall be smooth
and dense.
All irregularities, fins or risers shall be ground off flush with the adjacent surface.
Castings with visible cracks, blow holes, or similar blemishes shall be rejected if
the imperfections are located on bearing / surfaces or cannot be remedied to the
satisfaction of the Engineer. Imperfections which are not located on bearing
surfaces shall be cleaned out, filled with weld metal of the appropriate
composition and ground flush with adjacent surfaces.
2006.4.3 Structural steel assemblies : Defects arising from the fabrication of the steel shall
be inspected by the Engineer, who will decide whether the materials may be
repaired by the Contractor or will be rejected.
The cost of repairs or replacement shall be borne by the Contractor.
All steel whether fabricated or not, shall be stored above the ground on platforms,
skids, or other supports, and adequately protected against corrosion. Excessively
rusted, bent or damaged steel shall be rejected.
All plates shall be flat and rolled bars and shapes straight before marking out or
being worked. Straightening shall be done by methods which shall not damage
the material. Sharp kinks and bends shall be the cause for rejection.
Steel may be flame cut to shape and length so that a regular surface, free from
excessive gouges and striations is obtained. Flame cutting by hand shan be done
only with the approval of the Engineer.

Exposed comers shall be machined or ground.
2006.4.4 Tolerances
1. Plan dimensions : -0 to+5mm
2. Overall height: -0 to+3mm
3. Height of elastomer: ±5 percent
4. Height of any steel component
a) Machined: 0 to+1mm
b) Unmachined: Class 2 of IS:4897
5. Stainless steel sliding surface
a) Flatness: 0.0004L, where L= length in direction of measurement
b) Surface Finish: Ra ≤0.25 pm as per IS:3073
2006.4.5 Painting
i) All non-working surfaces shall be coated with two coats of epoxy primer and
one or more coat each of epoxy intermediate and finish, total thickness < 0.150
Jim or any other painting scheme as approved by the Engineer.
ii) Silicon grease shall be applied at the PTFE/SS interface after testing,
iii) Anchor sleeves shall be cement coated at the manufacturer's works.
2006.5 Test
2006.5.1 Raw materials: Necessary test certificates for all raw materials as in Clause
2006.3 above shall be furnished by manufacturers.
Reference may also be made to Clause 2005.1 for tests on elastomers.
2006.5.2 Test on casting: Tests specified in IS: 1030 shall be performed. Castings shall
be ultrasonically tested and certificates submitted.
Quality level.of castings shall be level 3 as per IS:9565.
2006.5.3 Test on welding: All welding shall be tested by Dye
Penetration method. But welding shall be tested by Ultrasonic method.
Soundness of welding shall be certified by the manufacturer.

2006.5.4 Acceptance test on bearing
i) All bearings shall be checked for overall dimensions.
ii) All bearings shall be load tested to 1.1 times maximum design capacity
including seismic force. Bearing tested at higher loads cannot be used.
iii) A pair of bearings selected at random will undergo testing in order to

determine the coefficient of friction "u.". The coefficient of friction shall be < 0.05
at the design load.
iv) Two bearings selected at random shall be tested for permiSSible rotation.
2006.6 Installation of POT-cum-PTFE Bearings
2006.6.1 General
i) Care shall be taken during installation of the bearings to permit their correct
functioning in accordance with the design scheme.
il) To prevent contamination, dismantling of the bearings at site shall not be done.
iii) The load shall be transferred onto the bearings only when the bedding
material has developed sufficient strength. The props for the formwork shall only
be removed after lapse of appropriate time. In special cases, this can be ensured
by suitable devices like jacks, etc.
iv) Temporary clamps and shims (introduced to maintain working clearance) shall
be removed at an appropriate time, before the bearing is required to permit
movement.
v) Permitted installation tolerance of the bearing from plane of sliding shall be

maintained.
vi) Cement based non-shrink grout with air releasing additive and epoxy based
grout, whichever is specified shall be first tried at the site. For the proprietary
grout mixes, appropriate instructions from the manufacturer shall be followed
specially with regard to the following:
a) Preparation->concrete cleaning, roughening, pre-soaking, etc.
b) Forms->sturdiness, leak proofing, shape, header funnel vents, etc.
c) Bearing Base->cleaning, etc,
d) Placement->mixing, consistency, time period, finishing, etc.
e) Protectlon->curing, ambient temperature, etc.

2006.6.2 In-situ casting of superstructure
I Formwork around the bearing shall be carefully sealed to prevent leakage.
ii) Sliding plates shall be fully supported and care taken to prevent tilting,
displacement or distortion of the bearings under the weight of wet concrete.
iii) Bearings shan be protected during concreting operation. Any mortar

contaminating the bearing shall be completely removed before it sets.
2006.6.3 Seating of bearing
A. Using Template
i) Template with required rigidity and matching holes corresponding to the base of
the bearing shall be used.
ii) All the anchors shall be fitted to the lower face of the template using the anchor
screws but with steel washer replacing the elastomer washers. Separate screws
may be used in case of inconvenience in the length of the original anchor screws.
iii) The template assembly shall be located with regard to level and alignment. It
shall be ensured that the top of the anchors lie in a horizontal plane at the
required elevation. The anchors shall be tied/welded to reinforcements to avoid
displacement during concreting.
iv) Concreting of the pedestal/pier cap shall be done to a level leaving a gap of
25-50 mm below the template.
v) The template- and steel washers shall be removed prior to placement of the
bearing assembly with temporary damps. The bearing assembly shall be fitted to
the anchors with the help of anchor screws and elastomer washers. level at the
bearing shall be checked.
vi) The gap below the bearing assembly shall be grouted with cement based
grout Reference may be made to Clause 2006.6.1 (vi).
B. Without Template with Gap
i) Pockets commensurate with the sizes of the anchors shall be kept in pedestals
during concreting of the same. The pedestal shall be cast approximately 25 mm
short of the required finished level.
ii) Anchors shall be fitted to the bearing bottom with elastomer washers and
anchor screws. The bearing assembly shall be seated in the location on steel
chairs/packs. The anchors fitted below the bearing shall go into pockets in the

bed block. level and alignment of the bearing shall be checked. it shall be
ensured that the bearing sits in a horizontal plane.
iii) The gap below the bearing assembly including anchor pockets shall be
grouted with cement based grout Reference may be made to Clause 2006.6.1
(vi).
C Without Template without Gap
Elongated pockets commensurate with the sizes of the anchors shall be kept in
pedestals during concreting of the same. The geometry and location of the
anchor pockets (with tapered funnel extension, if required) shall be such that after
placement of the bearing the pockets can be successfully grouted. The pedestal
shall be cast 5 mm - 15 mm short of the required finished level. The required
level shall be achieved by chipping before placement of the bearing. Careful
control shall be exercised to cast at the exact finished level or 1mm -3 mm down
from the required finished level.
D. Seating of bearings shall be as per manufacturer's instructions.
2007 INSPECTION AND TESTING
Where any patents are used, the manufacturer's certificate with test proofs shall
be submitted alongwith the design and got approved by the Engineer before their
use in work.
The materials shall be tested in accordance with these specifications and shall
The work shall conform to these specifications and shall meet the prescribed
Bearings shall be measured in numbers, according to their capacities and

particular specifications given on the drawings.
The quantity of elastomeric bearings shall be measured in cubic centimetres of

finished dimensions.

2010 RATE
The contract unit rate of each type of bearing shall include the cost of supplying
and fixing the bearings in position complete as specified on the drawings or as
decided by the Engineer.
The rate shall also include the cost of samples and their testing when desired by
the Engineer.
In case of steel bearings the rate shall include the cost of all nuts, bolts, the cost
of all tests prescribed in the specifications and shown on the drawings.
Where the Department supplies the bearings,.the rate for fixing them shall
include the cost of anchor bolts, their fixing, transport of bearings from the place
of supply to the site, handling and placing them in position as per direction of the
Engineer

2100 OPEN FOUNDATIONS

2101 DESCRIPTION
The work shall cover furnishing and providing plain or reinforced concrete
foundation placed in open excavation, in accordance with the drawings and these
specifications or as directed by the Engineer.
2102 MATERIALS
Materials shall conform to Section 1000 of these Specifications.
2103 GENERAL
A method statement for construction indicating the following shall be submitted by

the Contractor for approval of the Engineer, well in advance of the
commencement of open foundation:
i) Sources of Materials
ii) Design, erection and removal of formwork
iii) Production, transportation, laying and curing of concrete
iv) Personnel employed for execution and supervision
v) Tests and sampling procedures
vi) Equipment details
vii) Any other point
Necessary arrangements for execution under water wherever necessary, shall be

included in method statement.
Dimensions, lines and levels shall be set out and checked with respect to
permanent reference lines and permanent bench mark.
2104 WORKMANSHIP
2104.1 Preparation of Foundations
Excavation for laying the foundation shall be carried out in accordance with
Section 300 of these specifications. The last 300 mm of excavation shall be done
just before laying of lean concrete below foundation.
In the event of excavation having been made deeper than that shown on the
drawing or as ordered by the Engineer, the extra depth shall be made up with
M15 concrete in case of foundation resting on soil and foundation grade concrete
for foundations in rock, at the cost of the Contractor and shall be considered as

incidental work. Special care shall be taken not to disturb the bearing surface.
Open foundations shall be constructed in dry conditions and the Contractor shall
provide for adequate dewatering arrangements to the satisfaction of the
Engineer.
2104.2 Setting Out
The plan dimensions of the foundation shall be set out at the bottom of
foundation trench and checked with respect to original reference line and axis. It
shall be ensured that at no point the bearing surface is higher than the founding
level shown on the drawing or as directed by the Engineer.
2104.3 Construction
Where the bearing surface is earth, a layer of MI S concrete shall be provided

below foundation concrete. The thickness of lean concrete layer shall be 100 mm
minimum unless otherwise specified.
No formwork is necessary for the lean concrete layer. For foundation concrete
work, side formwork shall be used. Formwork for top of the foundation concrete
shall also be provided, if its top has slopes steeper than 1 (vertical) to 3
(horizontal). When concrete is laid in slope without top formwork, the slump of the
concrete shall be carefully maintained to ensure that compaction is possible
without slippage down the slope of freshly placed concrete. In certain cases it
may be necessary to build the top formwork progressively as the concreting
proceeds up the slope.
Reinforcement shall be laid as shown on the drawing.
Before laying of lean concrete layer, the earth surface shall be cleaned of all
loose material and wetted. Care shall be taken to avoid muddy surface.
If any portion of the surface has been spoiled by over-wetting, the same shall be
removed. Concrete M15 shall be laid to the thickness as required. No
construction joint shall be provided in the lean concrete.
Before laying foundation concrete, the lean concrete or hard rock surface shall be
cleaned of all loose material and lightly moistened.
Foundation concrete of required dimensions and shape shall be laid continuously

upto the location of construction joint shown on the drawing or as directed by the
Engineer.

Formwork and concrete shall conform to Sections 1500 and 1700 respectively of
these specifications. Furnishing and providing steel reinforcement shall conform
to Section 1600.
The concrete surface shall be finished smooth with a trowel. The location of
construction joint and its treatment shall be done as per requirements of Section
1700. Formwork shall be removed not earlier than 24 hours after placing of
concrete. Where form work has been provided for top surface, the same shall be
removed as soon as concrete has hardened.
Curing of concrete shall be carried out by wetting of formwork before removal.

After its removal, curing shall be done by laying not less than 10 cm of loose
moistened sand, free from clod or gravel and shall be kept continuously moist for
a period of 7 days.
Dewatering, where necessary for laying of concrete, shall be carried out adopting
anyone of the following procedures or any other method approved by the
Engineer:
i) A pit or trench deeper than the foundation level as necessary may be dug
beyond the foundation pit during construction so that the water level is kept below
the foundation level.
ii) Water table is depressed by well point system or other methods.
iii) Use of steel/concrete caissons or sheet piling for creating an enclosure for the
foundations, which can subsequently be dewaiered.
Before backfilling is commenced, loose sand laid on foundation shall be removed

and dispersed as directed by the Engineer.
All spaces excavated and not occupied by the foundation or other permanent
works shall be refilled with earth upto surface of surrounding ground in
accordance with Section 300. In case of excavation in rock, the annular space
around foundation shall be filled with M15 concrete upto the top of rock.
The protective works, where provided shall be completed before the floods so
that the foundation does not get undermined.

No point of the surface of the lean concrete in the case of foundation on soil or
the surface of hard rock in the case of foundation of hard rock, shall be higher
than the founding level shown on the drawing or as ordered by the Engineer.
levels of the surface shall be taken at intervals of not more than 3 metres centre
to centre, subject to a minimum of nine levels on the surface.
2106 TOLERANCES
a) Variation in dimensions +50mm ·10mm
b) Misplacement from specified position in plan 15mm
c) surface irregularities measured with :I m straight edge 5mm
d) Variation of levels at the top :1:25 mm
Excavation in foundation shall be measured in accordance with Section 300

based on the quantity ordered or as shown on the drawing.
Lean concrete shall be measured in cubic metres in accordance with Section

1700, based on the quantity ordered or as shown on the drawing.
Concrete in foundation shall be measured in cubic metres in accordance with

Section 1700, based on the quantity ordered or as shown on the drawing.
Reinforcement steel shall be measured in tonnes in accordance with Section

1600, based on the quantity ordered or as shown on the drawing.
2108 RATE
The contract unit rates for excavation in foundation, lean concrete and concrete
in foundation and reinforcement steel shall include all works as given in
respective sections of these specifications and cover all incidental items for
furnishing and providing open foundation as mentioned in this Section.

2200 SUB-STRUCTURE

2201 DESCRIPTION
The work shall cover furnishing and providing of masonry or reinforced concrete
sub-structure in accordance with the drawings and as per these specifications or
as directed by the Engineer.
2202 MATERIALS
2203 GENERAL
A method statement for construction indicating the following shall be submitted by

the Contractor for approval of the Engineer, well in advance of the
commencement of sub-structure:
ii) Design, erection and removal of formwork
iv) Personnel employed for execution and supervision
v) Tests and sampling procedures
vi) Equipment details
vii) Any other point
Arrangements for execution under water wherever necessary, shall be included

in method statement.
Dimensions, lines and levels shall be set out and checked with respect to
permanent reference lines and permanent bench mark.
2204 PIERS AND ABUTMENTS
Masonry, formwork, concrete and reinforcement for piers and abutments shall
conform to relevant sections of these specifications. In case of concrete piers, the
number of horizontal construction joints shall be kept minimum. Construction
joints shall be avoided in splash zones unless specifically permitted by the
Engineer and provided they are treated in accordance with special provisions. No
vertical construction joint shall be provided. The work shall conform strictly to the
drawings or as directed by the Engineer.
In case of tall piers and abutments, use of slipform shall be preferred.

The design, erection and raising of slipform shall be subject to special

specifications which will be furnished by the Contractor. The concrete shall also
be subject to additional specifications as necessary. All specifications and
arrangements shall be subject to the approval of the Engineer.
The surface of foundation/well cap/pile cap shall be scrapped with wire brush and
all loose materials removed. In case reinforcing bars projecting from foundations
are coated with cement slurry, the same shall be removed by tapping, hammering
or wire brushing. Care shall be taken to remove all loose materials around
reinforcements. Just before commencing masonry or concrete work, the surface
shall be thoroughly wetted.
In case of solid (non-spill.through type) abutments, weep holes as shown on the

drawings or as directed by the Engineer, shall be provided in conformity with
Section 2706.
The surface finish shall be smooth, except the earth face of abutments which
shall be rough finished.
In case of abutments likely to experience considerable movement on account of

backfill of approaches and settlement of foundations, the construction of the
abutment shall be followed by filling up of embankment in layers to the full height
to allow for the anticipated movement during construction period before casting of
superstructure.
2205 PIER CAP AND ABUTMENT CAP
Formwork, reinforcement and concrete shall conform to relevant sections of

these specifications.
The locations and levels of pier cap/abutment/cap/,pedestals and bolts for fixing
bearings shall be checked carefully to ensure alignment in accordance with the
drawings of the bridge.
The surface of cap shall be finished smooth and shall have a slope for draining of
water as shown on the drawings or as directed by the Engineer. for short span
slab bridges with continuous support on pier caps, the surface shall be cast
horizontal. The top surface of the pedestal on which bearings are to be placed
shall also be cast horizontal.
The surface on which elastomeric bearings are to be placed shall be wood float
finished to a level plane which shall not vary more than 1.5 mm from straight
edge placed in any direction across the area. The surface on which other

bearings (steel bearings, pot bearings) are to be placed shall be cast about 25
mm below the bottom level of bearings and as indicated on the drawings.
2206 DIRT/ BALLAST WALL, RETURN WALL AND WING WALL
Masonry, concrete and reinforcement shall conform to relevant sections of these

specifications.
In case of cantilever return walls, no construction joint shall generally be

permitted. Wherever feasible, the concreting in cantilever return walls shall be
carried out in continuation of the ballast wall.
For gravity type masonry and concrete return and wing wall, the surface of
foundation shall be prepared in the same manner as prescribed for construction
of abutment No horizontal construction joint shall be provided.
If shown on drawing or directed by the Engineer, vertical construction joint may

be provided. Vertical expansion gap of 20 mm shall be provided in return
wall/wing wall at every 10 metre intervals or as directed by the Engineer. Weep
holes shall be provided as prescribed for abutments or as shown on the
drawings.
Formwork, reinforcement and concrete in dirt/ballast wall shall conform to

relevant sections of these specifications.
The finish of the surface on the earth side shall be rough while the front face shall
be smooth finished.
Architectural coping for wing wall/return wall in brick masonry shall conform to
section 1300.
The. work shall conform to these specifications and shall meet the prescribed
2208 TOLERANCES IN CONCRETE ELEMENTS
(a) Variation in cross-sectional dimensions : +10 nun,
:-5mm
(b) Misplacement from specified position in plan: 10mm
(c) Variation of levels at the top: +10mm

(d) Variations of reduced levels of bearing areas: +5mm
(e) Variations from plumb over full height:+10mm
(f) Surface irregularities measured with 3 m straight edge
All surfaces except bearing areas: 5mm
Bearing areas: 3mm
Masonry in sub-structure shall be measured in cubic metres in accordance with

Section 1300 or 1400, based on the quantities ordered or as shown on the
drawing.
Concrete in sub-structure shall be measured in cubic metres in accordance with

Section 1700, based on the quantity ordered or as shown on the drawing. No
deduction shall be made for weep holes.
Steel in concrete of sub-structures shall be measured in tonnes, in accordance

with Section 1600, based on the quantity ordered or as shown on the drawing.
Weep holes shall be measured as per Section 2700, based on the quantity
ordered or as shown on the drawings.
2210 RATE
The contract unit rates for masonry, concrete, reinforcement and weep holes
shall include all works as given in respective sections of these specifications and
cover all incidental items for furnishing and providing substructure as mentioned
in this Section.

2300 CONCRETE SUPERSTRUCTURE

2301 DESCRIPTION
The work shall cover furnishing and providing of concrete superstructure in

accordance with the drawings as per these specifications or as directed by the
Engineer.
2302 MATERIALS
2303 GENERAL
2303.1 A method statement for construction, indicating the following, shall be submitted
by the Contractor for approval of the Engineer, well in advance of the
commencement of the construction of superstructure:
ii) Design, erection and removal of form work
iv) Prestressing system, if applicable
v) Personnel employed for execution and supervision
vi) Tests and sampling procedure
vii) Equipment details
viii) Any other point
2303.2 Dimensions, lines and levels shall be set out and checked with respect to
permanent reference lines and permanent bench mark so that the final product is
in accordance with the drawings or as directed by the Engineer.
2303.3 The work shall conform to the following sections besides stipulations in this
section with regard to specific type of construction:
i) Formwork Section 1500
ii) Steel Reinforcement Section 1600
iii) Structural Concrete Section 1700
Iv) Prestressing Section 1800
Additionally, some of the common types of superstructure construction shall have

features as discussed in this Section.

2304 REINFORCED CONCRETE CONSTRUCTION
2304.1 Solid Slabs
Where adjacent span of slab has already been cast, the expansion joint and filler
board shall be placed abutting the already cast span which shall form the shutter
on that side of the new span to be cast The whole of the slab shall be cast with
reinforcement embedded for the road kerb and railings. No other construction
joint shall be allowed except with the express permission of the Engineer.
Where wearing coat is required to be provided, after the deck slab has been cast,
the surface of the slab shall be finished rough, but true to lines and levels as
shown on the drawings, before the concrete has hardened. The areas of
construction joints shall be treated in the prescribed manner.
The top of the slab shall be covered with dean moist sand as soon as the top
surface is hardened. Curing shall be carried out as per Section 1700.
Where the slab is resting on bearings, the same shall be placed in position in
accordance with the drawings, before casting of deck slab.
2304.2 RCC T-Beam and Slab
Provision of construction joint shall conform to the drawings or as per directions

of the Engineer. No construction joint shall be provided between the bottom bulb
and the web. If not indicated on the drawing, construction joint may be provided
at the junction of the web and the fillet between the web and the deck slab with
the permission of the Engineer.
The portions of deck slab near expansion joints shall be cast alongwith
reinforcements and embedments for expansion joints. For this purpose, the
portion of deck slab near expansion joints may be cast in a subsequent stage, if
permitted by the Engineer.
The surface finish of the deck slab shall be finished rough but true to lines and
levels as shown on the drawings before the concrete has hardened. Care shall
be taken for setting of bearings as indicated on the drawings.
2305 PRESTRESSED CONCRETE CONSTRUCTION
2305.1 PSC Girder and Composite RCC Slab
PSC Girder may be precast or cast-in-situ as mentioned on the drawing
or as directed by the Engineer. Girders may be post-tensioned or pretensioned.

Where precast construction is required to be adopted, selection of casting yard

and details of methodology and of equipment for shifting and launching of girders
shall be included in the method statement.
In case of cast-in-situ construction, the sequence of construction- including side

shifting of girders, if applicable, and placing on bearings shall be in accordance
with the drawings.
The PSC girder constituting the top flange, web and the bottom flange shall be
concreted in a Single operation without any construction joint.
The portions of deck slab near expansion joints shall be cast along-with
levels as shown on the drawings before the concrete has hardened. Care shall
2305.2 Box Girder
Box girders may be simply supported or continuous. Simply supported box

girders shall have minimum construction joints as approved by the Engineer. In
the case of continuous box girders the sequence of construction and location of
construction joints shall strictly follow the drawings.
The box section shall be constructed with a maximum of one construction joint
located in the web below the fillet between the deck slab and web. If permitted by
the Engineer, one additional construction joint may be permitted and this
construction joint shall be located in the web above the fillet between the soffit
slab and web.
The portions of deck slab near expansion joints shall be cast alongwith
levels as shown on the drawings before- the concrete has hardened. Care shall

2305.3 Cantilever Construction
Continuity of untensioned reinforcement from one segment to the next must be

ensured by providing full lap length as necessary.
The design of the superstructure shall take into account the following, aspects
which form an integral part of the construction operations:
a) Stability against over-turning for each statical condition through which the
assembly passes, shall be checked.
b) Stresses at each preceding segment joint with the addition of every segment
or change of statical conditions shall be checked. The load of equipment as well
as construction live load shall be taken into account
c) Precambering of the superstructure during construction shall be done in such a

manner that the finally constructed structure under permanent load attains the
final profile intended in the drawings.
2306 TOLERANCES
2306.1 Precast Concrete Superstructure
Variation in cross-sectional dimensions:
a) upto and including 2m ±5mm

over 2m ±5mm
b) Variation in length overall and length between bearings: shall not exceed
+10 mm or ±0.1 per cent of the span length, whichever
is lesser
c) Permissible surface irregularities when measured with a 3 m straight edge or

template 5mm
2306.2 Cast-in-Situ Superstructure
a) Variations in thickness of top and bottom slab for box girders, top and bottom
flange for T-girders or slabs -5 mm to +10 mm
b) Variations in web thickness - 5 mm to +10 mm + 5mm
c) Variation in overall depth or width ±5mm
d) Variation in length overall and length between bearings: shall not exceed
+10mm or +0.1 per cent of the span length, whichever is lesser
e) Permissible surface irregularities when measured: 5 mm

with a 3 m straight edge or template
The work shall conform to these specifications and shall meet the prescribed
Concrete in superstructure shall be measured in accordance with Section 1700,

based on the quantity ordered or as shown on the drawings.
Steel reinforcement (untensionedj in superstructure shall be measured in

accordance with Section 1600, based on the quantity ordered or as shown on the
drawings.
High tensile steel (prestressing) in superstructure shall be measured in

accordance with Section 1800, based on the quantity ordered or as shown on the
drawings.
2309. RATE
The contract unit rates for concrete, steel reinforcement (untensioned) and high
tensile steel {prestressing} shall include ail works as given in respective sections
of these specifications and cover all incidental items for furnishing and providing
superstructure as mentioned in this section.

2400 EXPANSION JOINTS

2401 DESCRIPTION
This work shall consist of fabrication and placing of expansion joints as indicated
on the drawing and conforming to these specifications or as directed by the
Engineer.
2402 GENERAL
a) The expansion joints (EJ) shall be designed and duly got approved by the
Engineer. It shall cater for expected movement and rotation of the structure at the
joints and provide smooth riding surface. It shall also be easy for inspection,
maintenance and replacement
b) Expansion joints shall be robust, durable, water-tight and replaceable. Site

fabricated expansion joints shall be prohibited. Expansion joints shall be obtained
by the Engineer either directly or through the Contractor from approved
manufacturers and be of proven type.
c) For bridges with prestressed concrete superstructure, with individual span

length more than ,20 m or built with innovative design/construction elastomeric
expansion joints of slab seal or strip seal type shall be provided
d) For slab type of bridges of spans less than 10 metres continuous surfacing
may be provided across the expansion gaps, supported on a 20 mm thick plate
placed and fixed at the level of the deck slab.
e) For bridges other than those mentioned in (c) above with spans above 10
metres, an alternative specification of sliding steel plate joint or filled joints with
copper plates may also be adopted if approved by the Engineer, apart from
elastomeric expansion joint of slab seal or strip seal type.
f) Vehicular traffic shall not be allowed over expansion joints after its construction
for such period as may be determined by the Engineer.
g) Proprietary type deck joints offered by the Contractor in lieu of the type
specified shall comply in all respects with the manufacturer's specifications and
meet required the range of movements and rotations and be fit for the purpose of
ensuring satisfactory long term performance in the bridge.
h) Where alternative type proprietary deck joints are proposed by the Contractor,
the following information shall be provided.
i. Name and location of the proposed manufacturer.

ii. Dimensions and general details of the joint including material specifications,
holding down bolt or anchorage details and installation procedures.
iii. Evidence of satisfactory performance under similar environmental conditions

of similar joints being produced by the manufacturer.
Any acceptance of alternative type will be at the sole discretion of the Engineer.
Such deck joints shall be installed in accordance with the manufacturer's

recommendations and to the general requirements of this Specification.
No. expansion joint shall be provided only for the width of the carriageway. It shall
follow the profile including the kerb and the footway and facia, if provided. The
type of expansion joint for the latter may be made different from that used for the
carriageway expansion joint.
Salient sources of joint movements may be broadly grouped into external load
induced movements and internal volume changes of deck as given in Table
2400.1. (As per clause 4 of IRC SP:69:2011, Table 4.1)
Table 2400.1 Salient Sources of Joint Movement
Sources of External load induced Sources of Internal volume

movements changes of deck
Horizontal loads transmitted to deck

Ambient temperature
(traffic loads/climatic loads)
Displacement/rotation of deck edges

Creep of concrete deck
induced by vertical traffic loads
Foundation/substructure movement
Shrinkage of concrete deck
(soil deformation, earth pressure etc.)
2402.1 Suggested Criteria for Adoption of Different Types of Expansion Joints
Primary basis of selection of any joint shall depend on the movement capacity of
that joint in relation to the specific requirement of the particular structure.
Designer may select the type of joint depending on the form/movement/rotation
as indicated in Table 2400.2. No joint is necessary up to 6 mm movement of the
joint. It is recommended that mixing of different type of joints in any particular
structure should be avoided. (As per clause 5.4 of IRC SP:69:2011, Table 5.4.1.)
Table 2400.2 Criteria for Adoption of Different Types of Expansion Joints

Types of Recommended
Sl
expansion movement capacity & Special Consideration
No.
Joints suitability for adoption
Simply supported Only for decks with

spans on unyielding bituminous asphaltic wearing
support with movement coat. Steel plate may need
1) Buried Joint not exceeding 10 mm. replacement if found corroded
or distorted at the time of
relaying/renewal of wearing
coat.
Simply supported The sealant and joint filler

spans on unyielding would need replacement, if
2) Filler Joint
support with movement found damaged.
not exceeding 10 mm.
Simply supported Not to be used below - 5°C

spans with horizontal and above 5O°C. Only for
movement not decks with bituminous
exceeding 25mm. asphaltic wearing coat. Not
suitable for bridge with
longitudinal gradient more
Asphaltic than 2 percent and cross
3)
Plug Joint camber/super elevation
exciding 3 percent . Not:
suitable for curved spans and
spans resting on yielding
supports. The joint is
especially suitable for
rehabilitation works.
Simply supported or Limited capacity for

continuous spans with movement in the transverse
Compression
4) maximum horizontal direction. Chloroprene /
Seal Joint
movement not Closed Cell foam seal may
exceeding 40 mm or need replacement during

maximum gap not service.

exceeding 60mm.
Simply supported, Elastomeric seal may need

continuous construction replacement during service
Single Strip /
for maximum horizontal
5) Box Seal
movement and
Joint
maximum gap opening
upto 80 mm
Simply supported or Liable to excessive wear and

continuous spans for tear under high traffic
maximum horizontal intensity and may require
movement and frequent maintenance. Not
Reinforced
maximum gap opening suitable for bridges located in
6) Elastomeric
up to 80 mm heavy rainfall area, spans
Joints
resting on yielding support of
cantilever bridges and where
rotations and transverse
movements are high.
Large to very large Elastomeric seals and

movements, movable parts may need
continuous/cantilever replacement during service.
construction with right,
Modular skew or curved deck
7) Strip / Box having horizontal
Seal Joint movement in excess of
80 mm. Maximum gap
opening shall not
exceed 80 mm per
module of joint
For large movements Not suitable for joints

over 80 mm without involving differential vertical
8) Finger Joints significant rotation in movement / articulated
the horizontal plane. support and high transverse
Separate arrangement movements. The joint must

for making the joint be anchored adequately and

water light is to be effectively protected against
ensured. corrosion.
Simply supported or Liable to excessive wear and

continuous spans for tear under high traffic
maximum horizontal intensity and may require
Reinforced movement and frequent maintenance. Not
Coupled maximum gap opening suitable for bridges located in
9)
Elastomeric over 80 mm but upto heavy rainfall area, spans
Joint 230 mm resting on yielding support of
cantilever bridges and where
rotations and transverse
movements are high.
Notes: For movements larger than those indicated in the above table, reference
may be made to specialized literature for the design/selection of a suitable joint
which is site specific.
For skew and curved bridges and bridges having significant transverse
movements of the deck, special design requirements are necessary
2402.2 Joints for Small Openings (Movement upto 25 mm)
(As per clause 6 of IRC SP:69:2011)
Brief description of different types of joints for small movements (upto 25 mm),
along with their limitations, are given below:
2402.2.1 Buried joint (movement upto 10 mm)
Buried joint consists of continuously laid bituminous/asphaltic surfacing over the

joint gap bridged by a steel plate resting freely over the top surface of the deck
concrete. Tile joint is suitable for short span structure. Typical buried joint is
shown in Fig. 2400.1.

Limitations of Buried Joint are:
• Prone to deterioration due to cracking and squeezing of bituminous surfacing

and consequent bad riding quality.
• The road surfacing at joint location is required to be renewed frequently.
• Gradual rusting and deterioration of supporting steel plate because of its

inaccessibility for maintenance.
2402.2.2 Filler joint (movement upto 10 mm)
The components of Filler joint shall be at least 2 mm thick corrugated copper

plate placed slightly below the wearing coat, 20 mm thick compressible fibre
board to protect the edges, 20 mm thick pre-moulded joint filler, sealed with a
joint sealing compound, filling the gap up to the top level of the wearing coat.
Typical fil ler joint is shown in Fig. 2400.2.
Limitations of Filler Joint are:
• Life of the joint is short. Compressibility of filler gets reduced with age and thus
needs to be replaced soon.

2402.2.3 Asphaltic plug joint (movement upto 25 mm)
Asphaltic plug joint consists of a modified bitumen binder carefully selected,

single size aggregate, closure/bridging metallic plate and heat resistant foam
caulking/backer rod. This joint is especially suitable for rehabilitation works.
Typical asphaltic plug joint is shown in Fig. 2400.3.
Limitations of Asphaltic Plug Joint are:
• Prone to deterioration due to flow of material in wheel path in high ambient

temperature.
• The aggregate may get de-bonded from the bitumen matrix in winter with
subsequent potholing under traffic.
• Possibility of de-bonding of the plug from the adjoining asphalt surface.
• Reliable indigenous source for binder etc. yet to be established.
• Incorrect placement of materials results in tearing of the adjacent carriageway

pavement.

• Yielding of asphaltic material under the wheels of standing vehicles, brake and
acceleration forces combined with high environmental temperatures and the
development of rutting.
2402.3 Joints for Medium Openings (Movement over 25 mm and upto 80 mm)
The absorption of medium openings requires an elastic expansion element or an

expansion gap across the carriageway surface. For traffic safety, gaps in deck
slab below 5 mm or over 65 mm are not recommended. Thus, the expansion
movement of a simple gap construction is limited to 60 mm. Expansion joints for
medium openings consist of a sealing element, edge elements and fixing
elements.
2402.4 Compression seal joint (movement upto 40 mm)
Compression seal joint consists of steel armoured nosing at two edges of the
joint gap suitably anchored to the deck concrete and a preformed chloroprene
elastomer / closed cell foam joint sealer compressed and fixed into the joint gap
with special adhesive binder. The seal is supposed to remain in continual
compression due to pressing of the seal wall against joint faces throughout the
service life to ensure that the joint remains water tight and capable of repelling
debris. Typical compression seal joint is shown in Fig. 2400.4.
Limitations of Compression Seal Joint are:
• Contact ·pressure of seal with steel nosing, which is the key to effective sealing
mechanism, decay considerably with age. Hence more safeguards are required
during installation for desired level of compression in the seal.
• Susceptible to detachment of seals from nosing due to debris accumulation and

dynamic vehicular impact on nosing.
• More susceptible to vandalism.

2402.5 Single strip/box seal joint (movement upto 80 mm)
Single strip/box seal expansion joint consists of two edge beams with anchorages
and an elastomeric sealing element held firmly in the housings of edge beams
that guarantee the water tightness of the joint. The maximum gap between the
edge beams at road surface when the joint fully opens due to maximum
contraction of deck shall be limited to 80 mm for comfortable passage of the
traffic. The edge beams protect the adjacent bridge deck concrete from damage
due to vehicular impact and also transfer the vehicular load to the deck structure
through robust anchorage system Typical single strip seal joint is shown in Fig.
2400.5.
Seals of expansion gaps can be constructed as V-shaped sections (Fig. 2400.6)

or hollow sections (Fig. 2400.7). Movements are absorbed by the opening/closing
of these elements. Both shear headed stud type and loop type anchorage may be
used.

Limitations of Single Strip Seal Joint are:
• Open surface gap tends to accumulate too much of debris on the strip seal
element particularly near footpath and kerb.
• Noise generation during passage of vehicle over the open surface gap.
• Blocking of open surface gap by entrapped stones or hard pieces may generate
locked-in condition restraining free movement of structure
2402.6 Reinforced elastomeric joints (movement upto 80 mm)
This type of joint consists of reinforced elastomeric pads connected to a

supporting steel structure which itself is cast into the concrete structure of the
bridge. The joint accommodates movement by shear deformation of elastomer
and opening and closing of grooves at upper and lower surface. The maximum
movement is limited by the gap width. Typical reinforced elastomeric joint is
shown in Fig. 2400.8.
Limitations of Reinforced Elastomeric Joints are:
• In high volume and high-speed traffic areas, the rubber surface of the bearing
plate is susceptible to excessive wear which lowers the skid resistance
• Since the reinforced elastomeric pads of most of the elastomeric joints are
manufactured in 1 m to 1.5 m sections, there is a potential for water leakage at
the tongue and groove splicing of the elastomeric pads in the case of improper
installation.
• Additional water seal below the elastomeric seal is required for making it
waterproof.
• Horizontal force offered by the joint and transmitted to the bridge structure may
be considerable due to the high resistance of the elastomeric elements.

2402.7 Joints for Large Openings (Movement over 80 mm)
2402.7.1 Modular strip/box seal Joint
The modular strip/box seal expansion joint divides the total movement capacity in
to several smaller gaps. The joint consists of two edge beams, one or more
central/separation beams or lamellas oriented transversely to the traffic direction
forming the load carrying elements, and cross beams supporting individual or
multiple central beams to transfer the loads to the bridge deck through the
anchorage system. Centre beams and transverse support / cross beams are
connected by resilient or shock absorption system to dampen dynamic loading,
thus reducing the forces transmitted to the structure and anchorages. The shock
absorption system accommodates vertical and transverse movements apart from
longitudinal movement. The joint also contains gap control system, which allows
closing and opening of the joint and ensures that all modules open or close
equally. The joint is made watertight through mechanically locked sealing system
of elastomeric strip seals connected between the lamellas. The gap width
between the consecutive centre beams at the joint surface shall be limited to 80
mm when the joint opens fully due to maximum contraction of deck. Typical
details of a modular strip seal expansion joint are shown in Fig. 2400.9.
Limitations of Modular Strip/Box Seal Joint are:
• Numerous movable parts susceptible to fatigue and wear.
• Open surface gap tends to accumulate too much of debris on the strip seal
element particularly near footpath and kerb.
• Noise generation during passage of vehicles over the open surface gap
between transversely located center beams.

• Mechanically operated gap control system can lead to poor functioning of the
joint, particularly when individual gaps are blocked by stones or other hard
pieces.
2402.7.2 Finger Joints
The cantilever-toothed joint (Fig. 2400.10) also called finger joint, is a very robust
construction but with several disadvantages. The deformation capacity in the
crosswise direction is severely limited and vertical deformations of the joint can
prejudice traffic safety To accommodate small vertical deformations without
hazard, the free finger ends should be rounded. Finger joints with supported
fingers (Fig. 2400.11) have proved to be not as good as with cantilever fingers.

Limitations of Finger Joints:
• Additional arrangements are required for making it water-proof.
• It induces lot of noise.
• It cannot accommodate differential vertical movement and high transverse

movements.
2402.7.3 Reinforced coupled elastomeric joint
This type of joint consists of reinforced elastomeric pads connected to a

supporting steel structure which itself is cast into the concrete structure of the
bridge. The joint accommodates movement by shear deformation of elastomer
and opening and closing of grooves at upper and lower surface. This joint can
take up movement upto 230 mm. Typical Reinforced coupled elastomeric joint is
shown in Fig. 2400.12
Limitations of Reinforced Coupled Elastomeric Joint are:
• In high volume and high speed traffic areas the rubber surface of the joint is
susceptible to excessive wear, which also lowers the skid resistance.
• Since the reinforced elastomeric pads of most of the slab seal joints are
manufactured in 1 m to 1.5 m sections, there is a potential for water leakage at

the tongue and groove splicing of the elastomeric pads in the case of improper
installation.
• Additional water seal below the elastomeric seal is required for making it water
proof.
• Horizontal force offered by the joint and transmitted to the bridge structure may
be considerable due to the high resistance of the elastomeric elements.
2402.8 Suggested Criteria for Adoption of Different Types of Expansion Joints
Primary basis of selection of any joint shall depend on the movement capacity of
that joint in relation to the specific requirement of the particular structure.
Designer may select the types type of joint depending on the
form/movement/rotation as indicated in Table 2400.2. No joint is necessary up to
6 mm movement of the joint. It is recommended that mixing of different type of
joints in any particular structure should be avoided. However, single gap strip
seal joint and modular strip seal joint shall be regarded as the same type.
2402.9 SPECIAL TYPES OF JOINTS (As per clause 6 of IRC SP:69:2011)
This section of the guidelines is aimed to provide general information to attend

special requirements of very high longitudinal movement, high transverse
movement, special detailing of joints for high seismic zones, special low noise
modular joint system and requirement of anti-skid surface for very large modular
strip seal joints. For joints, for very high longitudinal and transverse movement,
only specialized manufacturers having proven experience in design, manufacture
and supply of such join Is shall be consulted from the design stage to evolve a
foolproof system design most suitable to the structure and site conditions,
climatic variables and other requirements to ensure proper execution and
performance of the joint.
a) Very high longitudinal movement: In design and construction of very large and
complex bridges, expansion joints 10 cater for very large longitudinal movement
are required. Specially designed modular strip seal/box seal expansion joint is the
most suitable type for such cases.
b) High transverse movement: For long span bridges and/or sharply carved
bridges and in high seismic zones, the transverse movement may also be
considerably higher. Specially designed modular strip seal/box seal expansion
joint is the most suitable to cater for very high transverse movement. The
requirement of high transverse movement can be met by special detailing of

joints e.g. using wider and deeper control boxes to allow high transverse
movement
c) Joints for high seismic zones: For long span bridges in high seismic zones,
modular strip seal expansion joints equipped with seismic fuse box duly tested in
a test laboratory may be used to isolate the joint from the structure during earth
quake and thereby avoiding designing the joints for high additional movement in
case of earthquake. Such isolation with seismic fuse ensures lesser damage to
the joint and also the structure during earthquake. Typical detailing of seismic
fuse is shown in Fig. 2400.13
d) Noise reduction: Noise reduction becomes, increasingly, an issue for densely

populated areas. The idea of this newly developed expansion joint combines the
advantages of the normal modular expansion joint with the advantage of the
finger joint. It is achieved by welding or bolting sinusoidal plates. which are called
noise leaves, on the top of the center/lamella beams. -The over-rolling tyre
cannot bang anymore on a transversal edge. It now rolls along a curved. diagonal
line, with the result that the tyre of the passing vehicle cannot develop noise with
the same strength as on transversely oriented beams. Test results show that the
noise development can be reduced by 80 percent.
e) Joints with anti-skid surface: Large modular expansion joints for extremely long
span bridge structures require a special safety concept to ensure secure rollover
of all kind of traffic, while ensuring safe transmission of braking force but
preventing skidding of vehicles on the exposed steel surface of the joints. While
smaller expansion joints require only coating for corrosion protection, very large
modular expansion joints require special treatment of the exposed joint surface. A
friction coefficient of 0.5 between coating and rubber must be ensured for a
service life time under all weather conditions and neither pollution nor excessive
radiation from should reduce the long term quality of the special anti skidding

coating. For modular strip seal joints with movement capacity larger than 1000
mm, the exposed steel surface should be provided with anti skid coatings.
2403 REQUIREMENTS
2403.1 The requirement criterion will be separately applicable for the expansion joint
proper and the transition zone of attachment to the deck.
2403.2 There are two types of performance requirements for the expansion joint proper
viz. from the necessity of the bridge and from the road users e.g. man, animal
and vehicle.
2403.3 Performance requirement with Respect to Bridge
The expansion joint shall:
a) Withstand the imposed load including the impact load from live load and other
sources.
b) Allow expansion and contraction movement due to temperature, creep,

shrinkage, prestressing and structural deformations.
c) Permit relative rotation in elevation and plan due to the causes as noted
above.
d) Be waterproof. Bridge deck expansion joint seals playa critical role in

preventing the degradation of the- structural components of the bridge system.
Without effective joint seals, water passes through the bridge deck and works
harmfully to corrode steel components and cause deterioration of the concrete.
Rain water gathers various corroding additives from the atmosphere and ·also
from the carriageway.
e) Ensure scaling. In case bridge deck joints are not sealed, apart from loss of
waterproofing, grit and other forms of road debris may enter the joint. Debris,
when impacted with the joint can seriously restrict the movement instead of
facilitating the same. In the case of proprietary joints being accepted for adoption,
the sealing shall be as specified by them.
f) Ensure long life by being resistant to corrosion.
g) Be easy to install.
h) Be easy to maintain. Replaceability of expansion joint shall be one of the basic

criteria for selection of type of expansion joint.

i) Be resistant to the materials likely to collect/spill over the deck in its normal
service.
2403.4 Performance Requirement with Respect to User
The expansion joint shall :
a) Provide smooth continuity at the top of the deck for riding comfort.
b) Be of skid resistant surface.
c) Be non-damaging to the rubber tyre.
d) Make minimum noise during vehicular crossing.
e) Ensure that animal paws and hooves should not get entangled where bridges
are used by animal drawn traffic.
f) Permit passing of bullock cart steel tyre for bridges where bullock carts ply.
g) look good aesthetically.
2403.5 Performance Requirement for Transition Zone
It is the zone of connection of joint assembly and the adjoining deck. The
expansion joint shall:
a) Permit transfer of generated forces without distress, i.e., without getting

uprooted. The purpose will not be served if the bonding is with the wearing coal
only. Anchorage must be provided with the deck structural element.
b) Ensure that surface in the transition zone stays undisturbed during long term
service.
2404 STEEL PLATE SLIDING EXPANSION JOINTS
a) In this type of buried joint, the wearing coat shall be made continuous over the
joint. The other alternative shall be to keep a gap in the wearing coat which is
filled up with a seal and filler, to be provided in extremely hot areas:
b) Materials for steel plates shall conform to Section 1900. The exposed metallic
components shall be galvanised or coated with approved anticorrosive paint. The
thickness shall be 20 mm or so for obtaining satisfactory performance.
c) Plates shall be placed to the line, grade and expansion gap shown on the
drawings with any adjustment required for temperature, particular care being
taken with the top of the plates.

d) Plates shall be firmly held in place during concreting by methods approved by

the Engineer.
e) Any temporary bolts or other fixings which prevent relative movement of the
adjacent parts of the joint shall be removed as soon as the concrete has set
sufficiently to hold the expansion plates in their correct positions. In any case,
temporary bolts or other fittings shall be removed within 6 hours of placing
concrete unless otherwise directed by the Engineer.
f) Care shall be taken to prevent damage to expansion joint plates or its coating.
g) If any damage occurs, the plates and coatings shall be restored by the
Contractor to the satisfaction of the Engineer.
h) Plates shall- be free of oil, rust, loose paint or other similar material before
coating.
(As per clause 7.1.1.3 and 7.1.1.4 of IRC SP:69:2011)
i) The steel plate shall be 12 mm thick. and 200 mm wide. The plate shall be
made of minimum number of pieces (not exceeding two pieces per traffic lane
width) welded together to form the required length.
j) 8 mm dia. 100 mm long nails, spaced at 300 mm centres along the centre line
of the plate shall be welded to the bottom surface of the steel plate to protrude
vertically into the joint gap in order to prevent dislodging of the plate.
k) The steel for plate and nails shall be weldable structural steel conforming to IS:
2062
l) The plate and the nails shall be protected against corrosion by galvanising or
any other approved anti-corrosive coating with a minimum thickness of 100
micron. These shall be completely free of oil, rust, loose paint or other similar
material before application of anti-corrosive coating
2405 FILLER JOINTS
a) The components of this type of joint shall be at least 2 mm thick corrugated

copper plate placed slightly below the wearing coat, 20 mm thick compressible
fibre board to protect the edges, 20 mm thick premoulded joint filler filling the gap
upto the top level of the wearing coat, sealed with a joint sealing compound
b) The material used for filling expansion joint shall be bitumen impregnated felt,
elastomer or any other suitable material, as specified on the
drawings.Impregnated, felt shall conform to the requirements of IS: 1838, and

shall be got approved from the Engineer. The joint filler shall consist of large
pieces and assembly of small pieces to make up the required size shall be
avoided.
c) Expansion joint materials shall be handled with care and stored under cover by
the Contractor to prevent damage.
d) Any damage occurring after delivery shall be made good to the satisfaction of
the Engineer and at the expense of the Contractor.
e) Joint gaps shall be constructed as shown on the drawings. Surfaces of joint

grooves shall be thoroughly cleaned with a wire brush to remove all loose
materials and dirt and debris, then washed or jetted out.
f) Pre-moulded expansion joint filler shall not be placed in position until

immediately prior to the placing of the abutting material. If the two adjacent
surfaces of the joint are to be placed at different times, this type of joint filler shall
not be placed until the second face is about to be placed.
g) Sealants shall be installed in accordance with the manufacturer's

recommendations and all appropriate requirements for joint face priming.
h) Sealants shall be finished approximately 3 mm below the upper surfaces of the

joint.
i) Joint materials spilt or splashed onto finished surfaces of the bridge during joint
filling operations shall be removed and the surfaces made good to the Engineer's
approval.
j) No joint shall be sealed until inspected by the Engineer and approval is given to
proceed with the work.
2406 ELASTOMERIC SLAB SEAL EXPANSION JOINT.
2406.1 Materials
a) Steel inserts shall conform to IS:224. Use of any other materials like fibre-glass
or similar material shall not be permitted.
b) Elastomer for elastomeric slab unit (ESU) shall conform to clause 915.1 of
IRC:83 (Part II), compounded to give hardness ERHO 60 +5, subject to the
following additional stipulations:
i. Chloroprene (CR) only shall be used in the manufacture of elastomeric

expansion joints. No reclaimed/natural rubber or vulcanised wastes shall be
used.

ii. The chloroprene material used in the manufacture of elastomeric (expansion

joints) shall be Neoprene WRT, Bayprene 110, Skyprene B5 or Denka S-40V.
iii. Chloroprene content of the compound sh.al! not be lower than 60 per cent by
weight The ash content shall not exceed 5 pr cent (as per tests conducted in
accordance with ASTM 0-297 for (i) and (ii) above.
iv. EPOM and other similar candidate elastomers for expansion joints shall not be
permitted.
c) Elastomeric plugs.
d) Spacer bars, marked with centre to centre distance of fixing holes.
e) Fixing bolts and nuts made of stainless steel.
f) Anchor bars comprising hooked anchor stiffeners welded with lower steel
inserts and sinusoidal anchor bars welded with horizontal leg of the edge steel
inserts. The elaborate anchoring arrangements of steel inserts shall be
permanently welded/ tied with the steel reinforcement.
2406.2 Fabrication
a) Steel inserts shall be grit blasted and provided with epoxy paint
b) Edges of reinforcing steel sections shall be rounded.
c) Expansion joints shall be fully moulded to the required- size in one single
vulcanising operation including the encasing layers as integral and homogeneous
part
d) Tolerances of fabrication shall be as follows:
i) Plan dimension -> ± 5 mm
ii) Total height- -± 3 mm
2406.3 Supply and Handling
i) The Contractor shall supply all steel-reinforced elastomeric expansion joints

including bolts, nuts, sealant, plugs and all other accessories for the effective
installation of the joints including angled jointing sections for kerbs.
ii) Expansion joint material shall be handled with care and stored under cover by
the Contractor to prevent damage. Any damage occurring after delivery shall be
made good at the expense of the Contractor to the satisfaction of the Engineer.

2406.4 Installation
2406.4.1 Expansion joints shall be installed as per approved drawing.
Steel inserts, spacer bars, concreting of pockets, fixing of elastomer slab unit and
presetting, etc., shall be done as per the following:
a) Steel Inserts
i) Deck casting shall be done leaving pockets or recess for steel inserts and
anchors of the expansion joint as per drawing.
ii) Steel inserts shall be lowered at the appropriate location inside the pocket
iii) The top of. the insert shall be flush with the finished level of wearing course
maintaining the camber.
iv) Spacer bars, duly set 'appropriately to the month of installation, shall be fitted
under proper supervision.
v) Anchor rods· shall be tied/welded with the existing deck main reinforcement,
maintaining level and alignment.
vi) Welding between anchor rods and deck reinforcement is preferable. If welding
is not possible, strong steel tie wires shall be used for fastening, under proper
supervision.
b) Spacer Bar
i) Spacer bars shall be used to ensure proper positioning of bolts and also
levelling of the steel inse'1s during fixing of the same with the deck reinforcement
and casting second stage concreting in the pocket thereafter.
ii) The 2nd stage concreting operation shall preferably be started within 24 hours
of fixing the steel inserts. In such cases, spacer bars should be removed just after
concreting is finished. If there is a substantial time lag between fixing of inserts
and concreting, then anyone of the following methods shall be adopted,
depending on the support condition:
a) For simply supported bridge resting on Simple elastomeric bearings, (with no

dowel pins), insert shall be placed in position with spacer bars at every alternate
joints. Such joints shall be called restrained joints hereafter. In other words,
inserts shall not be fixed simultaneously at two ends of one span. If the above
condition is satisfied, inserts with spacer bars shall be kept in position for a
substantially longer period at such restrained joints. Spacer bars shall be

removed after concreting of such restrained joints and inserts placed in position
with spacer bars at the other unrestrained joints thereafter.
b) For bridges resting on other than elastomeric bearings (including bearings with
dowel pins at one end), after placing and aligning the inserts and securing the
same, the spacer bars shall be removed. Concreting shall be done with great
care so that inserts are not dislocated or distorted.
iii) While removing the spacer bar after concreting, one must take care to see that
the concrete is not damaged during withdrawal of spacer bar. If the spacer-bar
happens to be snugly fitted, it shall not be pulled by any means; it shall be gas
cut in two pieces and then' removed.
c) Concreting of Pocket
i) Concreting of pocket shall be done with great care using proper mix conforming
to grade similar to that of the Check casting besides ensuring efficient bonding
between deck and steel insert.
Also proper care shall be given for ensuring efficient bonding with the already
cast concrete.
ii) Needle vibrators shall be used. Care shall be taken so that the position of steel
insert is not disturbed during vibration.
iii) Spacer bar shall be removed within an appropriate time before the joint is
required to permit movement.
d) Fixing of Elastomeric Slab Unit (ESU)
i) Special jig shall be used to preset the ESU during installation.
ii) ESU (mounted on the jig, if preset) shall be lowered to position
iii) The line and level on the ESU should be adjusted.
Iv) ESU shall be removed and coated with special adhesive
v) ESU shall be placed in position .again, ensuring waterproof joining at required

faces.
vi) ESU shall be tightened with stainless steel nuts and lock washers in position.
Tightened nuts shall be locked with lock washers.
vi) Special sealant shall be poured inside the plug holes.
vii) The elastomeric plugs shall be pressed in position after applying adhesive on
the appropriate surface.

viii) ESU shall be fitted in position after completion of wearing course. While
completing this part of the wearing course, adequate care shall be taken to
ensure a waterproof, joining with the already existing wearing course.
e) Pre-Setting
i) The main purpose of presetting of The steel inserts at the time of its installation
is to ensure as closely as possible the condition that in the long run at the mean
average annual temperature, the ESU remains at its nominal state.
ii) Major factors responsible for changing the longitudinal length of the bridge
superstructure are indicated below:
a) Temperature variation from annual mean.
b) Changes due to shrinkage of concrete.
c) Changes due to elastic shortening and creep of the prestressed bridge

superstructure.
d) Deformation of superstructure and substructure, if any
Resultant changes in expansion gap due to first factor can occur in both
directions from any pre-selected mean position whereas changes due to creep
and shrinkage are unidirectional such that the expansion gap continuously
increases with passage of time.
The steel insert unit of expansion joint can be fixed in any month of the year. As
stated earlier, the expansion gap between bridge superstructure may vary from
time to time; hence the initial fixing distance between fixing points will obviously
depend on the month of installation of steel insert. The c/c distance between
stainless steel fixing of bolts as indicated in the drawing can be taken as only
nominal. The same shall be modified by presetting depending on :
i) The difference between the mean temperature of the month of fixing £i steel
insert and the annual average temperature.
ii) The elapsed period between the casting and/or prestressing and fixing of steel
insert for calculating the remnant creep and shrinkage.
2406.4.2 Special requirements for installation
i) Prior to construction of bridge deck area adjacent to the joint, the supplier shall
provide detailed working drawings showing the location of all bolts, recesses and
holes necessary for the installation of the joint. Reinforcing bars in superstructure

shall be amended as required to ensure that there will be no interference in the

installation of the joint.
ii} All bearing surfaces and recesses which are in contact with the joint assembly
shall be checked with a straight edge to ensure flatness of profile.
iii) No holes shall be drilled for fixing bolts within 7 days of concreting. Holes for
the bolts shall be drilled to the size and depth shown on the drawings.
iv) Sections of the jointing making the completed joint shall follow a straight line.
v) The fixing bolts shall not be placed in a position until at least 4 weeks after
stressing is completed in post-tensioned box or beam and slab structures. Prior
to placing sections of jointing, contact surfaces shall be cleaned to remove all
grease, tar, paint, oil, mud or any other foreign material that may affect adhesion
of the sealant
vi) Sealant shall only be applied to dry contact surfaces. Sufficient sealant shall
be applied to the contact surfaces to cause extrusion of sealant when the jointing
is fixed in position.
vii) Final sealing of the finished expansion joint shall be completed immediately
after completion of installation. All exposed ends, joints between units and other
areas of possible leakage shall be filled with sealant. All voids between the sides
of the jointing and excrete or plates shall be filled with sealant.
viii) Bolt cavities shall be cleaned and plugged with neoprene cavity plugs. Prior
to placing the plugs sufficient sealant shall be placed in the cavities to cause
extrusion of the sealant by the plugs.
ix) All excess sealant shall be removed from the jointing and adjacent areas.
2406.5 Acceptance Test
2406.5.1 As per clause 918.7 of IRC-83 (Part II), necessary quality control certification by
the manufacturer in regard to properties of Elastomer and steel will be furnished.
For severe environment, ozone resistance test as per clause 915.2.3 of IRC:83
(Part II), shall be carried out for elastomer.
The properties of the elastomer shall conform to Table I of clause 915.2 of

IRC:83 (Part II). The acceptance testing for elastomer material Shall conform to
clause 918.4.1.2 of IRC:83 (Part II) with additional criteria as stated in Clause
2005.

2406.5.2 The fabricated expansion joint shall be subjected to the following acceptance
tests:
i) Routine test. Each expansion joint shall be tested for at least 100 cycles for a
test movement which shall be 10 per cent more than the design expansion/
contraction movement.
ii) In addition to routine test, one out of every 20 expansion joints shall be
subjected to the test movement for 4000 cycles.
The lot shall be rejected if the elastomer material shows signs of fatigue or
permanent set or distress in the test. The test piece shall not be used in the
bridge.
iii) The type test for abrasion resistance shall be carried out for one joint out of
every 20 nos. as per IS:3400 (Pare 3) and the standard deviation shall be within i
20 per cent
N.B. The manufacturer shall preferably have in-house testing. facility.
Otherwise, the testing shall be got done by him at his expense at any testing
establishment selected by the Engineer. A manufacturer who cannot carry out
the acceptance test shall not be entitled to supply elastomeric slab seal joint.
2407 SINGLE STRIP BOX SEAL EXPANSION JOINT
2407.1 Components
Strip seal expansion joint shall comprise the following items:
a) Edge beams - This special claw leg profiled member shall be of extruded rolled
steel section combining good weldability with notch toughness.
(As per clause 7.5.1.1 of IRC SP:69:2011)
This shall be either extruded or hot rolled steel section including continuously
shop welded section with suitable profile to mechanically lock the sealing element
in place throughout the normal movement cycle. Further, the configuration shall
be such that the section has a minimum thickness of 10 mm all along its cross-
section (flange & web). Thickness of lips holding the seal shall not be less than 6
mm. The minimum height of the edge beam section shall be 80 mm. The
minimum cross-sectional area of the edge beam shall be 1500 mm.
b) Strip seal - This shall be of chloroprene with high tear strength, insensitive to
oil, gasoline, and ozone. It shall have high resistance to aging. This component,
provided to ensure water tightness, shall have bulbous shape of the pan of the

seal which is inserted into the groove, provided in the edge beam. The seal
should be vulcanised in single operation for minimum full length of joint.
c) Rigid Anchorage - This shall be welded to the edge beam at staggered

distance.
(As per clause 7.5.1.2 of IRC SP:69:2011)
The edge beams of single strip/box seal joints shall be anchored in the concrete
with rigid loop anchorage or headed shear stud anchors. In case of headed shear
stud anchors it is to be ensured that the studs are anchored in concrete
adequately reinforced around the studs and are not in plane concrete shoulders.
The anchorage system shall satisfy the requirement. The anchor loops shall be
connected to the edge beam by means of anchor plates welded to the edge
beam. Total cross-sectional area of anchor loop or headed shear studs on each
side of the joint shall not be less than 1600 mm' per meter length of the joint and
the centre-to-centre spacing shall not exceed 250 mm for loop anchors and 150
mm for headed shear studs. The thickness of anchor plate shall not be less than
0.7 times the diameter of anchor loop or 12 mm whichever is higher. The anchor
at the edge profiles should be at a right angle to the joint. Planned deviations of
this direction are allowable only for the range of 90° +/- 20°, (The anchoring
reinforcement of the construction must lie parallel to the anchor loops).
d) Anchor loops - This shall be made of weldable steel connecting the rigid
anchorage with deck reinforcement.
2407.2 Material
a) The steel for edge beams shall conform to any of the steel grade equivalent to
RST 37-2 or 37-3 (DIN), S235JRG2 or S355K2G3 of EN10025 (DIN 17100),
ASTM A 36 or A 588, CAN/CSA Standard G40.21 Grade 300 W or Grade B of IS
2062. For subzero condition, material for steel shall conform to IS 2062 Grade C.
b) Chloroprene of strip seal shall conform to clause 915-1 of IRC:83 (Part II). The
properties of chloroprene shall conform to Table 2600-1 & Table 2600-2
Table 2601: Properties of Chloroprene Seal
Property Standard Specific Value
DIN 53505 63 +5 Shore A

Hardness
ASTM 02240* 55 + 5 Shore A

DIN 53504 Min. 11 MPa

Tensile Strength
ASTM D 412* Min 13.8 MPa
DIN 53504 Min. 350%

Elongation at fracture
ASTM 0 412* Min. 250%
Tear propagation strength
Longitudinal DIN 53507 Min. 10 N/mm
Transverse ASTM 0 264· (Dia C) Min. 10 N/mm
Shock elasticity DIN 53512 Min. 25%
Abrasion DIN 53516 Max. 220 mm3
DIN 53517
Residual compression strain Max. 28%
ASTM 0 395 (Method
(22h/70°C/30% strain)
B)
Ageing in hot air DIN 53508
(14 days/70°C)
Change in hardness Max. + 7 Shore A
Change in tensile strength Max.·20%
Change in elongation at fracture Max.-20%
Ageing in ozone
DIN 53509 No cracks
(24h/50 pphm/25°C/20% strain)

Swelling behavior in oil DIN 53521
(168h/25°'C )
ASTM oil No. 1
Volume change Max. + 5%,
Change in hardness Max.-10 Shore A
ASTM oil No. 3
Volume change Max. + 25%
Change in hardness Max.-20 Shore A
Cold hardening point ASTM 0 1043 Min. - 35°C
Note: Only one set of specification viz., ASTM or DIN shall be followed depending
on the source of supply.
Table 2600-2 Properties of Closed Cell Foam Seal
Property Specific Value
Density 41.7-51.3 kg/cu.m.
Compression Set on 25 mm 50 percent compression samples (ASTM

D 3575) for 22 hours at 23'C, 2 hour
recovery; 13 percent set.
Working temperature -70 to +70°C
Water absorption (total immersion for 0.09166 kg/Sq.m

3 months) .(ASTM 3575)
Tensile strength 0.8 MPa
Elongation at break (ASTM D 3575) 195+/- 20 percent
(As per clause 7.5.2.3 to 7.5.2.5 and 7.5.2.6 of IRC:SP 69: 2011)
All steel sections shall be protected against corrosion by one of the following two
methods –

(i) Hot dip galvanising with a minimum thickness of 150 micron
(ii) Epoxy coating- All surfaces of the steel inserts and anchorage including the
surfaces to be in contact with or embedded in concrete shall be sand/shot blasted
to SA 2Y, and provided with a coat of epoxy primer enriched with metallic zinc.
Surfaces not to be in contact with or embedded in concrete shall be provided with
an additional coat of epoxy primer enriched with metallic zinc, one intermediate
coat of high build epoxy paint reinforced with MIO (Micaceous Iron Oxide) and
one coat of high performance epoxy finish paint as per paint manufacturer's
specification with a minimum total dry film thickness of 150 micron.
Joints for which the gap width does not close fully, the movement capacity shall
be (80 - minimum opening) i.e. the capacity of the joint having a minimum
opening gap width of 20 mm will be 60 mm. Only for joints that close fully, the
movement capacity of joint shall be 80mm.
Minimum gap for inserting the chloroprene seals in the expansion joint shall be
25mm
c) Anchorage steel shall conform to IS:2062.
d) Anchor loop shall conform to IS:2062.
2407.3 Fabrication (Pre-installation)
a) Rolled steel profiles for edge beams shall be long enough to cater for a 2-lane
carriageway. These shall be cut to size of actual requirements by means of a
mitre box saw. Alignment of the cut-to-size steel profiles shall then be made in
accordance with the actual bridge cross-section on work tables. For this
purpose, the contour of bridge cross-section shall be sketched onto these tables.
After the steel profiles are aligned, they will be chucked to the tables by means of
screw damps and tacked by arc welding.
b) Anchor plates shall be cut to the required size by gas cutting. These shall be
welded to the edge beams.
c) Anchor loops shall be bent to the required shape and welded to anchor plates.
d) The finally assembled joints shall then be clamped and transported to the
work site.
2407.4 Handling and Storage
a) For transportation and storage, auxiliary brackets shall be provided to hold

the; joint assembly together.

b) The manufacturer shall supply either directly to the Engineer or to the Bridge
Contractor all the materials of strip seal joints including sealants and all other
accessories for the effective installation of the jointing.
c) Expansion joint material shall be handled with care. It shall be stored under
cover on suitable lumber padding by the Contractor to prevent damage. Any
damage occurring after delivery shall be made good at the Bridge Contractor's
expense to the satisfaction of the Engineer.

2407.5 Installation
2407.5.1 The width of the gap to cater for movement due to thermal effect, prestress,
shrinkage and creep, superstructure deformations (if any) and sub-structure
deformations (if any) shall be determined and intimated to the manufacturer.
Depending upon the temperature at which the joint is likely to be installed, the
gap dimension shall be preset.
2407.5.2 Taking the width of gap for movement of the joint into account, the dimensions of
the recess in the decking shall be established in accordance with the drawings or
design data of the manufacturer. The surfaces of the recess shall be thoroughly
cleaned and all dirt and debris removed. The exposed reinforcement shall be
suitably adjusted to permit unobstructed lowering of the joint into the recess.
2407.5.3 The recess shall be shuttered in such a way that dimensions in the joint drawing
are maintained. The formwork shall be tight.
2407.5.4 Immediately prior to placing the joint, the presetting shall be inspected. Should
the actual, temperature of the structure be different from the temperature
provided for presetting, correction of the presetting shall be done. After
adjustment, the brackets shall be tightened again.
2407.5.5 The joint shall be lowered in a pre-determined position. Following placement of

the joint in the prepared recess, the joint shall be levelled and finally aligned and
the anchor loops on one side of the joint welded to the exposed reinforcement
bars of the structure. Upon completion, the same procedure shall be followed for
the other side of the joint. With the expansion joint finally held at both sides, the
auxiliary brackets shall be released, allowing the joint to take up the movement
of the structure.
2407.5.6 High quality concrete shall then be filled into the recess. The packing concrete
must feature low shrinkage and have the same strength .as that of the
superstructure, but in any case not less than M 35 grade. Good compaction and
careful curing of concrete is particularly important. After the concrete has cured,
the movable installation brackets still in place shall be removed.
2407.5.7 Rolled up neoprene strip seal shall be cut into the required length and inserted
between the edge beams by using a crow bar pushing the bulb of the seal into
the steel grooves of the edge beams. A landing to a bead shall be formed in the

thickened end of the edges of the seal which would force the thickened end
against the steel beam due to wedge effect when the strip seal is buttoned in
place.
2407.5.8 As soon as the concrete in the recess has become initially set, a sturdy ramp
shall be placed over the joint to protect the exposed steel beams and neoprene
seals from site traffic. Expansion joint shall not be exposed to traffic loading
before the carriageway surfacing is placed.
2407.5.9 The carriageway surfacing shall be finished flush with the top of the steel
sections. The actual junction of the surfacing/wearing coat with the steel edge
section shall be formed by a wedge shaped joint with a sealing compound. The
horizontal leg of the edge beam shall be cleaned beforehand. It is particularly
important to ensure thorough and careful compaction of the surfacing in order to
prevent any premature depression forming in it,
Acceptance Test
i) All steel elements shall be finished with corrosion protection system.
ii) For neoprene seal, the acceptance test shall conform to the requirements
stipulated in Table 2600-1. It shall also be stretch tested. If a manufacturer is to
supply this type of joint, they will have to produce a test certificate accordingly
conducted in a recognised laboratory, in India or abroad.
iii) In view of the importance of the built up edge beams, special investigation of
fatigue strength of this section with anchorages to withstand 2 x 10* load change
cycles without showing signs of damage, will be required. The supplier shall
have to produce a test certificate in this regard, conducted in a recognised
laboratory, in India or abroad
Iv) The manufacturer shall produce test certificates indicating that anchorage
system had been tested in a recognised laboratory to determine optimum
configuration of anchorage assembly under dynamic loading.
v) The manufacturer shall satisfy the Engineer that water tightness test for the
type of joint has been carried out in a recognised laboratory to check the water
tightness under a water pressure of 4 bars.
vi) As strip seal type of joint is specialised in nature, generally of the proprietary
type, the manufacturer shall be required to produce evidence of satisfactory
performance of this type of joint.

The work shall conform to these specifications and shall meet .the prescribed
The expansion joint shall be measured in running metres. For filled joints, the
rate per running metre shall include the cost of sealant for the depth provided in
this drawing.
2410 RATE
The contract unit rate shall include the cost of all material, labour, equipment and
other incidental charges for fixing the joints complete in all respects as per these
specifications in the case of Bridge Contractor supplying the expansion joint. If
the manufacturer supplies the expansion joint directly to the Engineer, the cost of
installation, handling and fixing shall be borne by the Bridge Contractor.
2411 Asphaltic Plug Joint (As per IRC 69: 2011 clause 7.3)
This joint shall consist of a polymer modified bitumen binder, carefully selected
single size aggregate; closure/bridging metallic plate and heat resistant foam
caulking/backer rod.

2411.1 General
2411.1.1 The joint shall extend to the full depth of the wearing course down to structural
concrete. Where needed, a recess may be cut into the deck slab concrete to
accommodate the minimum required depth (75 mm) of the joint.
2411.1.2 The joint shall be provided over the entire width of the structure including kerb
and/or footpath. A recess in the kerb and/or footpath shall be made to allow the
joint to pass beneath them. The expansion gap in the adjoining kerbs and/or
footpaths shall be sealed with a suitable sealant such as polysulphide sealant.
2411.1.3 Asphaltic Plug Joint may be used to cater for a maximum horizontal movement
upto 25 mm and maximum vertical movement of 2 mm. This shall be certified by
the manufacturer/supplier of the joint.
2411.1.4 The minimum width (in traffic direction) of the joint shall be 500 mm and
maximum width shall be 750 mm.
2411.1.5 Minimum depth of joint shall be 75 mm and maximum depth shall not exceed 100
mm.
2411.1.6 The joint shall be capable of performing satisfactorily, within the temperature
(ambient) range of -5 to 50'C.
2411.2 Material
2411.2.1 Binder
The polymer modified bitumen binder shall have the capacity to fill the gaps and
voids between single size aggregate and to impart flexibility to accommodate
various design movements. It shall be a patented blend of bitumen, synthetic
polymer, fillers and surface active agent and shall be so formulated as to
combine necessary fluidity for the installation process, low temperature flexibility
and flow resistance at high ambient temperatures. The binder shall satisfy
following requirements:
Softening point :100°C minimum
Core penetration at 25°C, 0.1 mm (BS 2499) :100 mm max.
Flow resistance at 70°C, 5 hours (BS 2499) : 3 mm max.

Extension Test :5 cycle of extension to

50%
(blocks prepared as per ASTM D 1190 at a rate of 3.2 mm/hour
at 25°C and tested to limits as per BS 2499)
Safe heating temperature : 210°C
2411.2.2 Aggregates
The aggregate shall be single size aggregate chosen from basalt, granite, grit
stone or gabro group. The nominal size of aggregate shall be 12.5 mm for depths
of joints upto 75 mm and 20 mm for joints of more depths. The aggregate shall
not be flaky and the Flakiness Ir.dex shall not be more than 25 percent The
aggregate Shall satisfy grading requirements stipulated in Table 2400.3.
Table 2400.3 Grading Requirements of Aggregates
Nominal size of aggregates
IS Sieve Designation 20mm 12.5 mm
Percentage by weight passing the sieve
26.5 mm 100 -
19.9 mm 85 -100 100
13.2 mm 0- 35 85 - 100
09.5 mm 0-7 0-35
06.3 mm - 0-7
02.3 mm 0-2 0-2
600 micron - -
75 micron 0-1 0-1
The aggregates should have good (i) Polished Slone Value (PSV). (ii) Aggregate
Abrasion Value (AAV). (iii) Aggregate Impact Value (AIV) and (iv) Aggregate

Crush Value (ACV). In addition, surface characteristics should promote proper

adhesion. The following are the required values:
PSV > 60
AAV < 05
AIV < 18
ACV = 10-25
2411.2.3 Closure plate
The closure plate shall be weldable structural steel conforming to IS 2062. The
minimum thickness of steel plate shall be 6 mm and the width shall not be less
than 200 mm. Closure plate shall be provided with as large length as possible
and welded together to form the required length. The number of pieces shall not
be more than two per traffic lane width. It shall be provided with equidistant holes
at a maximum spacing of 300 mm centres for anchorage to the caulking / backer
rod along the longitudinal centre line of the plate. The plate shall be protected
against corrosion by galvanising or any other approved anti-corrosive coating
paint with a minimum thickness of 100 micron.
2411.2.4 Foam caulking/backer rod
A closed cell polyolefine or open cell polyurethane foam cylindrical caulking or

backer rod having diameter equal to 150 percent of the joint opening shall be
provided. It shall be heat resistant and possess good flexibility and recovery
characteristics with density of 25 to 30 kg/m3
2412 Compression Seal Joint
(As per clause 7.4 of IRC:SP:69-2011)
Compression seal joint shall consist of steel armoured nosing at two edges of the
joint gap suitably anchored to the deck concrete and a preformed chloroprene
elastomer or closed cell foam joint sealer compressed and fixed into the joint gap
with special adhesive binder.
2412.1 General
2412.1.1 Steel nosing
The steel nosing shall be of angle section ISA 100 x 100. The thickness of legs
shall not be less than 12 mm. The top face of the angle shall be provided with

Bleeder holes of 12 mm diameter spaced at maximum 100 mm centres so as to

ensure that there are no voids in the concrete beneath the angle.
2412.1.2 Anchorage
The steel nosing shall be anchored to the deck by headed shear studs or anchor
plates cast in concrete or a combination of anchor plates and anchor loops.
Anchor bars shall engage the main structural reinforcement of the deck and in
case of anchor plates and anchor loops, this shall be achieved by passing
transverse bars through the loops or plates. The minimum thickness of anchor
plates shall be 12 mm. Total cross sectional area of bars or headed shear studs
on each side of the joint shall not be less than 1600 sq .mm per m length of the
joint and the centre-to-centre spacing shall not exceed 250 mm for loop anchors
and 150 mm for headed shear studs. The ultimate resistance of each anchorage
shall not be less than 600 KN/mm any direction. Steel shall conform to Grade B
of IS 2062. For sub-zero condition, material for steel shall conform to IS 2062
Grade C.
2412.1.3 Joint seal
The sealing element shall be a preformed continuous chloroprene/closed cell

foam seal with high tear strength, insensitive to oil, gasoline and ozone. It shall
have high resistance to ageing and ensure water tightness. The seal should be
continuous for the full length of the joint required for carriageway, kerbs and
footpaths, if any. The seal shall cater for a horizontal movement upto 40 mm and
vertical movement of 3 mm.
2412.2 Material
2412.2.1 The material of steel nosing and anchorage conforming to weldable

structural steel as per IS 2062 Grade B shall be used.
2412.2.2 The physical properties of chloroprene / closed cell foam sealing element
shall conform to the following:
a) Chloroprene Seal
Shall be preformed extruded multi-web cellular section of chloroprene of such a

shape as to promote self removal of foreign material during normal service
operations. Chloroprene of joint seal shall satisfy the properties stipulated in
Table 2400.1.

b) Closed cell foam seal
Shall be of preformed non-extruded non-cellular section made from low density

closed cell, cross linked ethylene vinyl acetate, polyethylene copolymer that is
physically blown using nitrogen. The material shall possess properties as
indicated in the Table 2400.2.
c) Chemical tests
Chemical tests shall be performed on specimen elastomer and the properties

shall confirm to the values/standards indicated in Table 2400.4.
Table No. 2400.4
Adhesion Strength IS 3400 pt XIV 7 kN/m
Low temperature Young's modulus 70

ASTM D-797
stiffness N/mm2 (Max)
Ash Content IS 3400 pt XXII 5%
Polymer identification Comparison of Spectra

test (Infrared Spectra ASTM D 3677 with reference to sample
photometry) of polychloroprene
2412.2.3 Lubricant-cum-adhesive
The type and application of material used in bonding the preformed joint seal to
the steel nosing and concrete shall be as recommended by the
manufacturer/supplier of the seal system.
2412.2.4 Corrosion protection
All steel sections shall be protected against corrosion by hot dip galvanizing or
any other approved anti-corrosive coating with a minimum thickness of 150
micron.
2413 Modular Strip/Box Seal Expansion Joints (As per clause 7.7 of IRC: SP: 69-
2011)
2413.1 General
2413.1.1 A modular expansion joint consists of two or more modules/cells of individual

capacity 80 mm to cater to a horizontal movement in excess or 80 mm. It shall

allow movements in all three directions and rotation about all three axes as per
the design requirements. The structural system shall consist of two edge beams,
one or more central/separation beams or lamellas and cross support bars
supporting individuals or multiple central beams to transfer the loads to the bridge
deck through the anchorage system.
2413.1.2 Edge beams and central beams/lamella
This shall be either extruded or hot rolled steel section including continuously
shop welded section with suitable profile to mechanically lock the sealing element
in place throughout the normal movement cycle. Further, the configuration shall
be such that the section has a minimum thickness of 10 mm all along its cross-
section (flange & web). Thickness of lips holding the seal shall not be less than 6
mm. The minimum height of the edge beam section shall be 80 mm. The
minimum cross-sectional area of the edge beam shall be 1500 mm.
Centre beams/lamellas shall be either extruded or hot rolled/cold rolled steel

section including continuously shop welded section with suitable profile to
mechanically lock the sealing element in place throughout the normal movement
cycle. Further, the configuration shall be such that the section has a minimum
thickness of 10 mm all along its cross-section (flange and web). Thickness of lips
holding the seal shall not be less than 6 mm. The minimum height of edge beam
and central beam sections shall be 80 mm. Minimum cross-sectional area of
each edge beam shall be 1500 sq. mm.
2413.1.3 Anchorage
The edge beams of single strip/box seal joints shall be anchored in the concrete
with rigid loop anchorage or headed shear stud anchors. In case of headed shear
stud anchors it is to be ensured that the studs are anchored in concrete
adequately reinforced around the studs and are not in plane concrete shoulders.
The anchorage system shall satisfy the requirement. The anchor loops shall be
connected to the edge beam by means of anchor plates welded to the edge
beam. Total cross-sectional area of anchor loop or headed shear studs on each
side of the joint shall not be less than 1600 mm' per meter length of the joint and
the centre-to-centre spacing shall not exceed 250 mm for loop anchors and 150
mm for headed shear studs. The thickness of anchor plate shall not be less than
0.7 times the diameter of anchor loop or 12 mm whichever is higher. The anchor
at the edge profiles should be at a right angle to the joint. Planned deviations of

this direction are allowable only for the range of 90° +/- 20°, (The anchoring
Studs and/or loop anchors with anchor plate may be used as anchorage of other
components like joist box, covers of controlling system etc
2413.1.4 Sealing element
This shall be a preformed/extruded single strip of such a shape as to promote

self-rermoval of foreign material during normal joint operation. The seal shall
possess high tear strength and be insensitive to oil, gasoline and ozone. It shall
have high resistance to ageing. The specially designed proprietary type of locking
system of seal in the housing of edge beam shall be such to ensure 100 percent
water tightness as well as ease of installation and replacement. Mechanical
fastening of sealing element with edge beam shall not be permitted. Sealing
element shall be continuous over the entire joint.
2413.1.5 Joints for which the gap width of modules do not close fully, the movement
capacity shall be (80 - minimum opening) x number of modules, i.e. the capacity
of a 5 module joint having a minimum opening gap width of 20 mm will be 60 x 5
i.e. 300 mm. Only for joints that close full y, the movement capacity of each
module shall be 80 mm.
2413.1.6 Support and control system
The control system should allow closing and opening of the joint and also ensure
that all modules open and close equally during all movement cycles of the joint.
The overall support and control system shall be either single/multiple support bar
control system or swivel joist system comprising of resilient / shock absorption
components and elastic/sliding control system in form of sliding bearings and
sliding springs conforming to the specifications recommended by the
manufacturer. The control system shall be such that the gap width is
independently flexible i.e. to allow full 80 mm gap width in one gap when all the
other gaps are fully closed. The center to center spacing of transverse support
bar shall not exceed 1.75 m.

2413.1.7 Minimum gap for inserting the neoprene seals in the expansion joint shall be 25
mm.
2413.2 Material
2413.2.1 The steel for edge beams, centre beam/lamella, transverse support bar and other
steel components shall conform to any of the steel grade corresponding to RST
37-2 or 37-3 or 52-3 (DIN ), S235JRG2 or S355K2G3 of EN10025 (DIN 17100),
ASTM A36 or A588, CAN/CSA standard G40.21 Grade 300 W.
2413.2.2 The material for sealing element shall conform to Table 2400.4 for Chloroprene
Rubber (CR).
2413.2.3 The specification for all other materials shall be as per original manufacturer's
recommendation.
2413.2.4 All steel sections shall be suitably protected against corrosion by one of the
following two methods - (i) Hot dip galvanising with a minimum thickness of 150
micron (ii) Epoxy coating- All surfaces of the steel inserts and anchorage
including the surfaces to be in contact with or embedded in concrete shall be
sand/shot blasted to SA 21/2.Surfaces not to be in contact with or embedded in
concrete shall be provided with zinc metal spray galvanising or a coat of epoxy
primer enriched with metallic zinc, one intermediate coat of high build epoxy paint
reinforced with MIO (Micaceous Iron Oxide) and one coat of high performance
epoxy/polyurethane finish paint as per paint manufacturer's specification with a
minimum total dry film thickness of 150 micron.
2414 Finger Joints
2414.1 General
2414.1.1 Steel fingers
This shall be either forged steel section or machined from single pieces of steel
plates.
Projection of Fingers made of welded section shall not be used. Finger type joints
shall be made watertight as shown in Fig. 2400.10 and 2400.11
2414.1.2 The finger joints shall be anchored in the concrete with rigid loop anchorage or
headed shear stud anchors. In case of headed shear stud anchors, it is to be

ensured that the studs are anchored in concrete adequately reinforced around
the studs and not in plane concrete shoulders. The anchorage system shall
satisfy the requirement of Clause 8.2.1. The anchor loops shall be connected to
the edge beam by means of anchor plates welded to the edge beam. Total cross-
sectional area of anchor loop or headed shear studs on each side of the joint
shall not be less than 1600 mm' per meter length of the joint and the centre-to-
centre spacing shall not exceed 250 mm for loop anchors and 150 mm for
headed shear studs. The thickness of anchor plate shall not be less than 0.7
times the diameter of anchor loop or 12 mm whichever is higher. The anchor at
the edge profiles should be at a right angle to the joint. Planned deviations of this
direction are allowable only for the range of 90° +/- 20°. (The anchoring
2414.2 Material
2414.2.1 The steel for edge beams shall conform to any of the steel grade corresponding
to RST 37-2 OR 37-3 (DIN), S235JRG2 or S355K2G3 of EN10025 (D IN 17100),
ASTM A36 or A 588, CAN/CSA Standard G40.21 Grade 300 W or equivalent to
Grade B of IS 2062. For subzero condition, material for steel shall conform to IS
2062 Grade C.
2414.2.2 All steel sections shall be protected against corrosion by one of the following two
methods - (i) Hot dip galvanising with a minimum thickness of 150 micron (ii)
Epoxy coating- All surfaces of the steel inserts and anchorage including the
surfaces to be in contact with or embedded in concrete shall be sand/shot blasted
to SA 211, and provided with a coat of epoxy primer enriched with metallic zinc.
Surfaces not to be in contact with or embedded in concrete shall be provided with
an additional coat of epoxy primer enriched with metallic zinc, one intermediate
coat of high build epoxy paint reinforced with MIO (Micaceous Iron Oxide) and
one coat of high performance epoxy finish paint as per paint manufacturer's
specification with a minimum total dry film thickness of 150 micron.
2414.2.3 Anchorage steel shall conform to Grade B of IS 2062 or equivalent standard.
2415 TESTING AND ACCEPTANCE STANDARDS
(As per clause 8 of IRC:SP:69-2011)

2415.1 This section of the guidelines is aimed to lay-down the pre-installation criteria of
acceptance based on predetermined methods of evaluation including testing of
materials.
2415.2 Before installing joints in a bridge, sufficient evidence of the reliability of the
proprietary products must be furnished. II copy of the fatigue and wear test
reports, as applicable depending upon the type of joint, carried out by a
recognized laboratory / university/ institute on the joint components as a part of
product development test shall be furnished once for the entire lot of supply. The
tests covered in Clause 2415.1 to 2415.5 need not be carried out on the
materials of the joints of supply Iot but should be carried out from time to time by
the original manufacturer as per their product development and quality plan for
the same type of joints to ensure the performance requirement of the particular
joint component against fatigue and/or wear.
2415.3 For single strip seal, modular strip seal and finger joints the manufacturer shall
produce complete repolt of the test of anchorage system in a recognised
laboratory to determine optimum configuration of anchorage assembly under
dynamic loading support of the efficacy of the anchorage system adopted for the
joints of entire lot of supply.
2415.4 For modular strip seal joints, the manufacturer shall produce a test report from a
recognised laboratory that the sliding bearings have been fatigue tested for 6 x
106 (6 million) load cycles with a frequency of 5 Hz. The durability test should be
carried out for 3 loads levels viz., 80 kN, 120 kN and 160 kN.
recognised laboratory that the wearing of sliding interface of bearings of modular
joints has been tested for a total sliding distance of 5000 m at a load of 48 kN.
recognised laboratory that the sliding material of sliding springs of expansion
joints has been tested for a total sliding distance of 20,000 m with a load
equivalent to a stress of 30 MPa.
recognised laboratory that the butt-welded splicing of centre beams has been
tested with 2 x 106 (2 million) load cycles with a frequency of 5.55 Hz and a load
equivalent to a stress of 165 MPa.

2415.8 In case of Reinforced Elastomeric Joints / Reinforced Coupled Elastomeric

Joints, abrasion resistance test shall be carried out in accordance with IS:3400
(Pt 3) or DIN 53516.
2415.9 An expansion joint assembly in a bridge deck shall have minimum number of
joints, subject to the manufacturer's specification for the proprietary products.
2416 Pre-installation Criteria
The pre-installation criteria should include the following off-site tests.
2416.1 Routine tests
Routine tests including tests for materials conforming to specifications shall be

carried out by the original manufacturer i.e., in case of imported joints by the
foreign manufacturer as part of their quality control procedure for all joints to be
supplied by them. Detailed documentation of all the tests and inspection data as
per complete quality control procedure shall be supplied by the original
manufacturer in the form of Quality Control Report. Routine tests shall primarily
include:
• Raw materials inspection.
• Process inspection.
• Complete dimensional check as per approved drawings.
2416.1.1 Raw material inspection
Tests on all raw materials used for the manufacturing of joints as per relevant
material standards based on this specification shall be carried out by the
manufacturer.
2416.1.1.1 Confirmation of the grade of steel
Grade of the steel for the edge beam should be confirmed by conducting tests for
yield stress, tensile strength, elongation etc. corresponding to RST 37-2 or 37-3
or 52-3 (DIN), S235 JRG2 or S355K2G3 of EN10025 (DIN 17100), ASTM A36 or
A588, CAN/CSA standard G 40.21 grade 300W or equivalent to Grade B of IS
2062. The manufactures/suppliers shall have in-house testing facilities for
conducting these tests
2416.1.1.2 Steel for the anchorage should conform to IS 2062 for Single gap
Strip Seal Joints.

2416.1.1.3 The following tests as indicated in Table 2400.1 should be made for
checking the properties of the chloroprene seal: (a) Hardness (b) Tensile strength
(c) Elongation at fracture (d) Tear propagation strength (e) Residual compressive
strain (f) Change in hardness (g) Change in tensile strength (h) change in
elongation at fracture (i) Ageing in ozone and (j) Swelling behaviour in oil. The
manufactures/suppliers shall have in -house testing facilities for conducting these
tests.
2416.1.2 Process inspection
Process inspection generally including inspection of all manufacturing processes

adopted to manufacture the joints e.g., welding, corrosion protection, clamping,
presetting. greasing, bonding by adhesives, riveting etc., as appropriate, shall be
carried out by the manufacturer.
2416.1.3 Complete dimensional check
Complete dimensional check of all components of joint as well as the assembled

joint with respect to the approved drawings and tolerances as per this
specification, shall be carried out by the manufacturer.
2416.2 Acceptance tests
In addition to the tests specified under Clause 2416.1.1 the manufacturer as well
as the local supplier in case of imported joints should have complete in-house
testing facilities for the following tests mentioned under Clause 2416.2.1 to
2416.2.4. These tests, as applicable (Table 2400.5), shall be carried out by the
manufacturer once in every six months and records shall be maintained. Test
specified in Clause 2416.2.5 should however be carried out on Modular Strip/Box
Seal Joint at least once which shall be certified by an external institute/university
of international repute. The client should insist upon these records before
acceptance of the joint.
2416.2.1 Cyclic motion
Cyclic motion test may be carried out once on one meter sample piece selected
at random from the entire lot of supply for each type of joint irrespective of
movement capacity. The test sample shall be fixed to the test frame using
fastening baits and subjected to 5000 expansion and contraction cycles @
minimum 30 cycles per hour. The test movement shall be 10 percent more than
the design/contraction movement. Any sign of distress or permanent set of any

component or the assembly due to fatigue will cause rejection of entire lot of
supply.
2416.2.2 Ponding
Water shall be continuously ponded along one meter length of joint for a
minimum period of 4 hours for a depth of 25 mm above the highest point of joint
top. The width of ponding shall be at least 50 mm beyond the anchorage block of
the joint on either side. The depth of water shall not fall below 25 mm anytime
during the test. A close inspection of the underside of the joint shall not reveal
any leakage.
2416.2.3 Debris expelling test
Debris expelling test shall be carried out on one meter sample piece selected at
random from the entire lot of supply. The fully open gap shall be filled with
granular debris flush with joint top and cycled 25 times for full opening and
closing. The mass of debris repelled after 25 cycles shall be expressed as the
percentage of initial mass. The percentage expelled shall not be less than 75
percent.
2416.2.4 Pull-out test
Pull-out test shall be carried out on one meter sample piece selected at random
from the entire lot of supply. The Joint shall then be stretched until the sealing
element slips oft from its housing. The minimum stretching of the joint before slip-
off shall be at least 150 percent of the rated movement capacity of the seal.
2416.2.5 Opening Movement Vibration (OMV) test
The Opening Movement Vibration (OMV) test is designed to test the ability of the
Modular Expansion Joint to withstand the repeated movement demands of the
bridge superstructure while being subjected to a simulated traffic load. The OMV
test simulates the most common movement of the joint, the movement due to the
daily thermal expansion and contraction of the superstructure by opening and
closing the expansion joint with an actuator. Traffic loads are simulated by
attaching a powerful pneumatic vibrator to one of the lamella / centre beams. This
test shall be carried out in accordance with NCHRP Report 467. The joint should
be tested for the equivalent of 75 years of 365 daily thermal cycles.

2416.2.6 Arrangement for protection of steel sections against corrosion should be

checked.
2416.3 Applicability of acceptance tests on different types of-joints
The acceptance tests described in Clause 2416.2 shall be applicable as per

Table 2400.5 for different types of joints:
Table 2400.5 Applicability of Acceptance Tests on Different Types of Joints
Buried Reinforced
Performanc
Joint/ Filler Elastomeric Single Gap Modular
e Finger Compression
Joint/ Coupled Strip/Box Strip/Box
evaluation Joint Seal Joint
Asphaltic Elastomeric Seal Joint Seal Joint
tests
Plug Joint Joint /
Not
Cyclic Not
Applicabl Applicable Applicable Applicable Applicable
motion Applicable
e
Not
Not Applicable
Ponding Applicabl Applicable Applicable Applicable
Applicable *
e
Debris Not
Not Applicable
expelling Applicabl Applicable Applicable Applicable
Applicable *
test e
Not
Not Not Not Applicable
Pull-out test Applicabl Applicable
Applicable Applicable Applicable *
e
* For modular strip seal expansion joint ponding test, debris expelling test and
pull-out test shall be carried out on one meter edge beam samples only, complete
with sealing element and anchorage.
Note: Since the above mentioned joints are proprietary products. clients may like
to ensure a suitable specified minimum guarantee period for joints considering
overall service life of structure.

2500 PIPE CULVERTS

2501 SCOPE
This work shall consist of furnishing and installing reinforced cement concrete
pipes, of the type, diameter and length required at the locations shown on the
drawings or as ordered by the Engineer and in accordance with the requirements
of these Specifications.
2502 MATERIALS
All materials used in the construction of pipe culverts shall conform to the
requirements of Section 1000.
Each consignment of cement concrete pipes shall be inspected, tested, if

necessary, and approved by the Engineer either at the place of manufacture or
at the site before their incorporation in the works.
2503 EXCAVATION FOR PIPE
The foundation bed for pipe culverts shall be excavated true to the tines and
grades shown on the drawings or as directed by the Engineer. .The pipes shall
be placed in shallow excavation of the natural ground or in open trenches cut in
existing embankments, taken down to levels as shown on the drawings. In case
of high embankments where the height of fill is more than three times the
external diameter of the pipe, the embankment shall first be built to an elevation
above the top of the pipe equal to the external diameter of the pipe, and to width
on each side of the pipe of not less than five times the diameter of pipe, after
which a trench shall be excavated and the pipe shall be laid.
Where trenching is involved, its width on either side of the pipe shall be a
minimum of 150 mm or one-fourth of the diameter of the pipe whichever is more
and shall not be more than one-third the diameter of the pipe. The sides of the
trench shall be as nearly vertical as possible.
The pipe shall be placed where the ground for the foundation is reasonably firm.
Installation of pipes under existing bridges or culverts shall be avoided as far as
possible. When during excavation the material encountered is soft, spongy or
other unstable soil, and unless other special construction methods are called for
on the drawings or in special provisions, such unsuitable material shall be
removed to such depth, width and length as directed by the Engineer. The
excavation shall then be backfilled with approved granular material which shall
be properly shaped and thoroughly compacted upto the specified level.

Where bed-crock or boulder strata are encountered, excavation shall be taken

down to atleast 200 mm below the bottom level of the pipe with prior permission
of the Engineer arid all rock/boulders in this area be removed and the space
filled with approved earth, free from stone or fragmented material, shaped to the
requirements and thoroughly compacted to provide adequate support for the
pipe.
Trenches shall be kept free from water until the pipes are installed and the joints
have hardened.
2504 BEDDING FOR PIPE
The bedding surface shall provide a firm foundation of uniform density

throughout the length of the culvert, shall conform to the specified levels and
grade, and shall be of one of the following two types as specified on the
drawings:
(i) First Class bedding: Under first class bedding, the pipe shall be evenly
bedded on a continuous layer of well compacted approved granular material,
shaped concentrically to fit the lower part of the pipe exterior for atleast ten per
cent of its overall height or as otherwise shown on the drawings. The bedding
material shall be well graded sand or another granular material passing 5.6 mm
sieve suitably compacted/rammed. The compacted thickness of the bedding
layer shall be as shown on the drawings and in no case shall it be less than 75
mm.
(ii) Concrete cradle bedding: When indicated on the drawings or directed by the
Engineer, the pipe shall be bedded in a cradle constructed of concrete having a
mix not leaner than M 15 conforming to Section 1700. The shape and
dimensions of .the cradle shall be; as indicated on the drawings. The pipes shall
be laid on the concrete bedding before the concrete has set.
2505 LAYING OF PIPE
No pipe shall be laid in position until the foundation has been approved by the
Engineer. Where two or more pipes are to be laid adjacent to each other, they
shall be separated by a distance equal to at least half the diameter of the pipe
subject to a minimum of 450 mm.
The arrangement for lifting, loading and unloading concrete pipes from
factory/yard and at site shall be such that the pipes do not suffer any undue

structural strain, any damage due to fall or impact. The arrangement may be got
Similarly, the arrangement for lowering the pipe in the bed shall be got approved
by the Engineer. It may be with tripod-pulley arrangement or simply by manual
labour in a manner that the pipe is placed in the proper position without damage.
The laying of pipes on the prepared foundation shall start from the outlet and
proceed towards me inlet and be completed to the specified lines and grades. In
case of use of pipes with bell-mouth, the belled end shall face upstream. The
pipes shall be fitted and matched so that when laid in work, they form a culvert
with a smooth uniform invert.
Any pipe found defective or damaged during laying shall be removed at the cost
of the Contractor.
2506 JOINTING
The pipes shall be jointed either by collar jOint or by flush joint. in the former
case, the collars shall be of RCC150 to 200 mm wide and having the same
strength as the pipes to be jointed. Caulking space shall be between 13 and 20
mm according to the diameter of the pipe. Caulking material shall be slightly wet
mix of cement and sand in the ratio of 1:2 rammed with caulking irons. Before
caulking, the collar shall be so placed that its centre coincides with the joint and
an even annular space is left between the collar and the pipe.
Flush joint may be internal flush joint or external flush joint. In either case, the
ends of the pipes shall be specially shaped to form a self centering joint with a
jointing space 13 mm wide. The jointing space shall be filled with cement mortar,
1 cement to 2 sand, mixed sufficiently dry to remain in position when forced with
a trowel or rammer. Care shall be taken to fill all voids and excess mortar shall
be removed.
For jointing pipe lines under light hydraulic pressure, the recess at the end of the
pipe shall be filled with jute braiding dipped in hot bitumen or other suitable
approved compound. Pipes shall be so jointed that the bitumen ring of one pipe
shall set into the recess of the next pipe. The ring shall be thoroughly
compressed by jacking or by any other suitable method.
All joints shall be made with care so that their interior surface is smooth and
consistent with the interior surface of the pipes. After finishing, the joint sha.1I be
kept covered and damp for at least four days.

2507 BACKFILLING
Trenches shall be backfilled immediately after the pipes have been laid and the
jointing material has hardened. The backfill soil shall be clean, free from
boulders, large roots, excessive amounts of sods or other vegetable matter, and
lumps and shall be approved by the Engineer. Backfilling upto 300 mm above
the top of the pipe shall be carefully done and the soil thoroughly rammed,
tamped or vibrated in layers not exceeding 150 mm, particular care being taken
to thoroughly consolidate the materials under the haunches of the pipe.
Approved pneumatic or light mechanical tamping equipment can be used.
Filling of the trench shall be carried out simultaneously on both sides of the pipe
in such a manner that unequal pressures do not occur.
In case of high embankment, after filling the trench upto the top of the pipe in the
above said manner, a loose fill of a depth equal to external diameter of the pipe
shall be placed over the pipe before further layers are added and compacted.
2508 HEADWALLS AND OTHER ANCILLARY WORKS
Headwalls, wing walls, aprons and other ancillary works shall be constructed in
accordance with the details shown on the drawings or as directed by the
Engineer. Masonry for the walls shall conform to Section 1300,1400 or 1700 as
applicable. Aprons shall conform to Section 2500.
2509 OPENING TO TRAFFIC
No traffic shall be permitted to cross the pipe line unless height of filling above
the top of the pipe line is atleast 600 mm.
R.C.C. pipe culverts shall be measured along their centre between the inlet and
outlet ends in linear metres.
Selected granular material and cement concrete for pipe tfedding shall be
measured as laid in cubic metres. Ancillary works like headwalls, etc., shall be
measured as provided for under the respective Sections.
2511 RATE
The Contract unit rate for the pipes shall include the cost of pipes including
loading, unloading, hauling, handling, storing, laying in position and jointing
complete and all incidental costs to complete the work as per these
Specifications.

Ancillary works such as excavation including backfilling, concrete and masonry

shall be paid for separately, as provided under the respective Clauses.

2600 APPENDICES

APPENDIX – 1200/1-1
HISTORY OF SINKING OF WELL. ………………………………….
LOWEST BED LEVEL ________ LOWEST WATER LEVEL _______ HIGHEST FLOOD LEVEL _______ FOUNDING LEVEL ___________
DATE STEINING
REDU TOTAL
CED HEIGHT OF REPORT
RL OF RL OF HEIGHT ROL OF SINKING RL OF REPORT
LEVEL STEINING DEPTH QUANTITY REGARDIN SIGNAT
TOP OF TOP OF OF REFERENCE BOTTOM BOTTOM ANY
(RL) (INCLUDING INITIAL FINAL OF STRA ECENTR OF G URE OF
STEININ STEININ STEINING LEVEL (AT OF OF ECENTRICI SPECIAL
OF CURB AND GAUGE GAUGE SUMP TA WEIGHT ICITY DREDGED OBSTACLE REMAR SUPERV
G G CAST WHICH CUTTING CUTTING TY ALONG METHOD
BOTTO CUTTING READING READING BELOW MET TONNES ALONG MATERIAL S OR SAND KS ISING
BEFORE AFTER (COL 4, CUTTING EDGE EDGE Y-AXIS OF
M OF EDGE METER METER CUTTIN WITH X-AXIS CUBIC BELOW OF
CASTIN CASTIN COL 3) EDGE IS (COL7, (COL7, SINKING
CUTTI (COL4, G EDGE METER DURING FICER
G G METER PLACED) COL 8) COL 8) EMPLOYED
NG COL3) SINKING
EDGE METER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

APPENDIX – 1200/H
REDUCED LEVELS (R.L’S) OF GAUGE MARKS SHIFT

TILT
TILT
ALONG X-
ALONG Y- RESULTANT SIGNATUR
TOTAL AXIS RESULTANT ACTION
TOTAL AXIS TILT E OF
STENIN COLUMN TILT TAKEN FOR
DATE SIIKING COLUMN 9 ALONG X- ALONG Y – REMARKS SUPERVISI
G 6 RECTIFICA
METER DEVIDED AXIS WITH AXIS WITH NG
METER ALONG X AXIS ALONG Y AXIS DEVIDED TION
BY WELL DIRECTION DIRECTION OFFICER
BY WELL
DIA METER METER
DIA
METER
DIFFREN
DIFFRENC
(PLAC CE
(PLACE) E (COL.5 –
E) (U/S) (D/S) (COL.8–
END COL4)
END COL7)
METER
METER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Appendices
Appendix -1500/1
INFORMATION TO BE SUPPLIED BY THE MANUFACTURES OF

PROPRIETARY SYSTEM
1. GENERAL
1.1. The information which the manufacturer is required to supply shall be in

such detail as to obviate unsafe Use of the equipment due to the intention of the
manufacturer not having been made clear or due to wrong assumptions on the
part of the user.
1.2 The user shall refer unusual problem or problems of erection/assembly not in
keeping with the intended use of the equipment, to the manufacturer of the
equipment.
2. INFORMATION REQUIRED
2.1 The manufacturers of proprietary systems shall supply the following

information:
a) Description of basic functions of equipment
b) List of items of equipment available, giving range of sizes, spans and such
like, with the manufacturer's identification numbers or other references.
c) The basis on which the safe working loads have been determined and
whether the factor of safety given applies to collapse or yield.
d) Whether the supplier's data is based on calculations or tests. This shall be

clearly stated as there may be wide variations between results obtained by either
method.
e) Instructions for use and maintenance, including any points which require
special attention during erection, especially where safety is concerned.
f) Detailed dimensional information, as follows:
(i) Overall dimensions and depth and widths of members.
(ii) line drawings including perspectives and photographs showing normal uses.
(iii) Self weights.
(iv) full dimensions of connections and any special positioning arrangements.
(v) Sizes of members, including tube diameters and thicknesses of materials.

(vi) Any permanent camber built into the equipment.
(vii) Sizes of holes and dimensions giving their positions.
g) Data relating to strength of equipment as follows:
(i) Average failure loads as determined by tests.
(ii) Recommended maximum working loads for various conditions of use.
(iii) Working resistance moments derived from tests.
(iv) Working shear capacities derived from tests.
(v) Recommended factors of safety used in assessing recommended loads and

deflections based on test results.
(vi) Deflections under load together with recommended pre-camber and limiting
deflections.
(vii) If working loads depend on calculations, working stresses should be stated.

If deflections depend on theoretical moments of inertia or equivalent moments of
inertia rather than tests, this should be noted.
(viii) Information on the design of sway bracing against wind and other horizontal
loadings.
(ix) Allowable loading relating to maximum extension of bases and/or heads.

Appendices
Appendix -1500/1
SPECIFICATIONS FOR GROUTING OF POST-TENSIONED
CABLES IN PRESTRESSED CONCRETE
1. GENERAL
1.1. The recommendations cover the cement grouting of post-tensioned tendons

of prestressed concrete members of bridges.
This also covers some of the essential protective measures to be adopted for
minimizing corrosion in PSC bridges.
1.2. The purpose of grouting is to provide permanent protection to the post-

tensioned steel against corrosion and to develop bond between the prestressing
steel and the surrounding structural concrete. The grout ensures encasement of
steel in an alkaline environment for corrosion protection and by filling the duct
space, it prevents water collection and freezing.
2. MATERIALS
2.1. Water
Only clean potable water free from impurities conforming to section 1000 shall
be permitted. No sea or creek water is to be used at all.
2.2. Cement
Ordinary Portland cement should be used for preparation of the grout. It should
be as fresh as possible and free of any lumps.
Pozzolana cement shall not be used.
2.3. Sand
It is not recommended to use sand for grouting of prestressing tendons. In case

the internal diameter of the ducts exceeds 150mm, use of sand may be
considered. Sand used shall conform to IS:383 and shall pass through 15 5ieve
No. 150. The weight of sand in the grout shall not be more than 10 per cent of
the weight of cement, unless proper workability can be ensured by addition of
suitable plasticizers.
2.4. Admixtures

Acceptable admixtures conforming to IS:9102 may be used if tests have shown

that their use improves the properties of grout, Le. increasing fluidity, reducing
bleeding, entraining air or expanding the grout. Admixtures must not contain
chlorides, nitrates, sulphides, sulphites or any other products which are likely to
damage the steel or grout. When an expanding agent is used, the total
unrestrained expansion should not exceed 10 per cent. Aluminum powder as an
expanding agent is not recommended for grouting because its long term effects
are not free from doubt.
2.5. Sheathing
2.5.1. For specifications of sheathing, section 1800 may be referred
2.5.2. Grout openings or vents
(a) All ducts should have grout openings at both ends.
For this purpose special openings should be provided where such openings are
not available at end an chorages. For draped (curved) cables vents shall be
provided at all crown and valley points. It is a good practice to provide additional
air vents at suitable intervals not exceeding 20m. All grout openings or vents
should include provisions for preventing grout leakage.
(b) Standard details of fixing couplers, inlets, outlets and air vents to the
duct/anchorage shall be followed as recommended by the supplier of the
prestressing system.
2.5.3. Ducts should be securely fastened at dose intervals. All untended holes or
openings in the duct must be repaired prior to concrete placing. The joints of the
couplers and the sheathing should be made water proof by use of adhesive tape
or similar suitable system capable of giving leak proof joints. Grout openings and
vents must be securely anchored to the duct and to either the forms or to
reinforcing steel to prevent displacement during concreting operations due to
weight, buoyancy and vibrations.
2.5.4. Ducts require very careful handling as, being of thin metal, they are
susceptible to leakage due to corrosion in transit or storage, by tearing/ripping in
handling particularly when placed adjoining to reinforcing steel, by pulling apart
at joints while inserting tendons prior to concreting, or by accidental puncturing
while drilling for form ties/inserts. Ducts are also liable to damage by rough use
of internal vibrator and sparks from welding being done close by.
3. EQUIPMENT

3.1. Grout Mixer and Agitator
It is essential that the grout is maintained in a homogeneous state and of uniform

consistency so that there is no separation of cement. Use of grout mixers to
obtain a colloidal grout is essential. The mixer should have an additional storage
device with an agitator to keep the grout moving continuously before it is pumped
in the duct. Positive reciprocating type grout pumps should be used.
3.2. Grout Pump
The pump should be positive displacement type and should be capable of

ejecting the grout in a continuous operation and not by way of pulses. The grout
pump must be fitted with a pressure gauge to enable pressure of injection to be
controlled. The minimum pressure at which grout should be pumped shall be 0.3
MPa and the grout pump must have a relief arrangement for bypass of the grout
in case of build up of pressure beyond 1 MPa.
The capacity of the grout pump should be such as to achieve forward speed of
grout of around 5 to 10 metres per minute. The slower rates are referable as
they reduce the possibility of occurrence of voids. If the capacity of the pump is
large, it is usual to grout two or more cables simultaneously through a common
manifold.
Use of hand pumps for grouting, is not recommended. Use of compressed air
operated equipment for injection is prohibited, as it is likely that there will be
some air trapped in grout.
3.3. Water Pump
Before commencement of grouting, a stand by direct feed high pressure water

pump should be available at site for an emergency. In case of any problem in
grouting the ducts, such pump shall immediately be connected to the duct and all
grout flushed by use of high pressure water flushing. It is, therefore, necessary
to have adequate storage of clean potable water for operation of the water pump
for such emergencies.
3.4. Grout Screen
The grouting equipment should contain a screen having a mesh size of 106
micron size of 150 microns if sand is used. Prior to introduction into the grout
pump, the grout should be passed through such screen. This screen should be
easily accessible for inspection and cleaning.

3.5. Connections and Air Vents
Standard details of fixing inlets, outlets and air vents to the sheathing and/or
anchorage should be followed as recommended specialist supplier of the system
of prestressing. In general, all connections are to be of the "Quick couple" type
and at change of diameters suitable reducers are to be provided.
4. PROPERTIES OF THE GROUT
4.1. Water/cement ratio should be as low as possible, consistent with workability.

This ratio should not normally exceed 0.45.
4.2. Before grouting, the properties of the grout mix should be tested in a
laboratory depending on the facilities available. Tests should be conducted for
each job periodically. The recommended test is described below.
4.3. Compressive Strength : The compressive strength of 100mm cubes of the

grout shall not be less than 17 MPa at 7 days. Cubes shall be cured in a moist
atmosphere for the first 24 hours and subsequently in water. These tests shall be
conducted in advance to ascertain the suitability of the grout mix.
5. MIXING OF GROUT
5.1. Proportions of materials should be based on field trials made on the grout
before commencement of grouting, but subject to the limits specified above. The
materials should be measured by weight.
5.2. Water should be added to the mixer, first, followed by Portland cement and
sand, if used. Admixture if any, may be added as recommended by the
manufacturer.
5.3. Mixing time depends upon the type of the mixer, but will normally be
between 2 and 3 minutes. However, mixing should be for such a duration as to
obtain uniform and thoroughly blended grout, without excessive temperature
increase or loss of expansive properties of the admixtures. The grout should be
continuously agitated until it is injected.
5.4. Once mixed, no water shall be added to the grout to increase its fluidity.
5.5 Hand mixing is not permitted.
6. GROUTING OPERATIONS
6.1. General

a) Grouting shall be carried out as early as possible but not later than 2 weeks of
stressing a tendon. Whenever this stipulation cannot be complied with for
unavoidable reasons, adequate temporary protection of the steel against
corrosion by methods or products which will not impair the ultimate adherence of
the injected grout should be ensured till grouting. The sealing of the anchorage
end after concreting is considered to be a good practice to prevent ingress of
water. For structures in aggressive environment, sealing of the anchorage ends
is mandatory.
Notes:
i) Application of some patented water soluble oils for coating of steel/VPI powder
injection/sending in of hot, dry, oil-free compressed air through the vents at
frequent intervals have shown some good results.
ii) Some of the methods recommended for sealing of anchorages are to seal the
openings with bitumen impregnated gunny bag or water proof paper or by
building a brick pedestal plastered on all faces enclosing the exposed wires
outside the anchorages.
iii) Any traces of oil if applied to steel for preventing corrosion should be removed
before grouting operation.
iv) Ducts shall be flushed with water for cleaning as well as for wetting the
surfaces of the duct walls. Water used for flushing should be of same quality as
used for grouting. It may, however, contain about 1 per cent of slaked lime or
quick lime. All water should be drained thorough the lowest vent pipe or by
blowing compressed air through the duct.
v) The water in the duct should be blown out with oil free compressed air.
Blowing out water from duct for cables longer than SOm draped up at both ends
by compressed air is not effective, outlet/vent provided at or near the lowest
point shall be used to drain out water from duct.
vi) The connection between the nozzle of the injection pipe and duct should be
such that air cannot be sucked in.
vii) All outlet points including vent openings should be kept open prior to
commencement of injection grout.
viii) Before grouting, all air in the pump and hose should be expelled. The suction
circuit of the pump should be air-tight.

6.2 Injection of Grout
a) After mixing the grout should be kept in continuous movement.
b) Injection of grout must be continuous and should not be interrupted.
c) For vertical cable or cables inclined more than 60 degrees to the horizontal,
injection should be effected from the lowest of the space to be filled by the
injected grout with the quantity of grout actually injected.
d) The method of injection should ensure complete filling of the ducts. To verify
this, it is advisable to compare the volume of the space to be filled by the
injected grout with the quantity of grout actually injected.
e) Grouting should be commenced initially with a low pressure of injection of

upto 0.3 MPa increasing it until the grout comes out at the other end. The grout
should be allowed to flow freely from the other end until the consistency of the
grout at this end is the same as that of the grout at the injection end. When the
grout flows at the other end, it should be closed off and building up of pressure
commenced. Full injection pressure at about 0.5 MPa shall be maintained for at
least one minute before closing the injection pipe. It is recommended practice to
provide a stand pipe at the highest point of the tendon profile to hold all water
displaced by sedimentation or bleeding. If there is a built up of pressure much in
excess of 1 MPs without flow of grout coming at the other end, the grouting
operation should be discontinued and the entire duct flushed with high pressure
water. Also, the bypass system indicated in para 3.2 above is essential for
further safety.
f) In the case of cables draped downwards e.g. in cantilever construction

simultaneous injection from both ends may be adopted Fig. 1800/111-1.
g) Grout not used within 30 minutes of mixing should be rejected.
h) Disconnection is facilitated if a short length of flexible tube connects the duct

and injection pipe. This can be squeezed and cut off after the grout has
hardened.
7. PRECAUTIONS AND RECOMMENDATIONS FOR EFFECTIVE GROUTING
a) In cold and frosty weather, injection should be postponed, unless special

precautions are taken. If frost is likely to occur within 48 hours after injection,
heat must be applied to the member and maintained for at least 48 hours after
injection so that the temperature of the grout does not fall below 5 degrees

Celsius. Prior to commencement of grouting, care must be taken to ensure that

the duct is completely free of frost/ice by flushing with warm water, but not with
steam.
b) The temperature of the grout shall not exceed 25 degrees Celsius. For
increasing the workability of grout, its temperature may be lowered by use of
chilled water, or by putting ice outside the grout storage container.
c) When the cables are threaded after concreting, the duct must be temporarily
stiffened during concreting by inserting bunch of strands, wires or reinforcement
or a rigid PVC pipe or any other suitable method.
d) During concreting, care shall be taken to ensure that the sheathing is not
damaged. Needle vibrators shall be used with extreme care by well experienced
staff only, to ensure against such damage.
e) It is a good practice to move the cables in both directions during the

concreting operations. This can easily be done by light hammering the ends of
the wires/strands during concreting. It is also advisable that 3 to 4 hours after
concreting the cable should be moved both ways through a distance of about 20
cms. With such movement, any leakage of mortar which has taken place in spite
of all precautions, loses bond with the cables, thus reducing . the change of
blockages. This operation can also be done by fixing prestressing jacks, et one
end pulling the entire cable and then repeating the operation by fixing the jack at
the other end.
f) The cables to be grouted should be separated by as much distance as

possible.
g) In case of stage prestressing, cables tensioned in the first stage should not
remain ungrouted till at cables are stressed. It is good practice, while grouting
any duct in stage prestressing, to keep all the remaining ducts filled up with
water containing 1 per cent lime or by running water through such ducts till the
grout has set.
After grouting the particular cable, the water in the other cables should be
drained and removed with compressed air to prevent corrosion.
h) Care should be taken to avoid leaks from one duct to another at joints of
precast members in particular.
i) End faces where anchorages are located are vulnerable points of entry of
water. They have to be necessarily protected with an effective barrier. Recesses

should be packed with mortar concrete and should preferable be painted with
water proof paint.
j) After grouting is completed, the projecting portion of the vents should be cut off
and the face protected to prevent corrosion.

Appendices
Appendix - HOO/IV
GROUTING RECORD
JobName: ___________________________________________________
Span No. ____________________ Cable No. : _______________________
Date of Cable Installation: _______________ Date of Grouting: __________
Type of Cement: OPC/IISOPC
Weak and Year of Manufacture of OPC/IIS0PC
W/C Ratio:
Name and amount of admixture used, if any ___________ _
Temperature: Mixing Wate ____ _: Grout
Time: _________ Start _____ _: Finish ______ _
Equipment: Grout mixer ___ _: Grout pump ___ _
Cable duet: Diameter ____ _: Length _____ _
Volume of grout in iitres ______ _: Regrouting ____ _
Grouting pressure ________ _
Cement consumption: Theoretical ___ _: Actual _________ __
Pre-grouting checks:
Free of blockage Inlet: Yes/No: Outlet Yes/No
Vents Vents: Yes/No Cable duct Yes/No
leakage observed : Yes/No : Sealed : Yes/No
If cable duet blocked: Remedial Measure ___________ _
Grouting observations:
Passage of grout through vents Yes/No
Passage of grout through outlet Yes/No
Any equipment failure : _________________________
Post grouting checks
Probbing by stiff wire : _________________________
Remarks : _________________________
Signatures of officers present during grouting:
Client Contractor System Supplier

MUNICIPAL CORPORATION OF GREATER MUMBAI BRIDGE DEPARTMENT TECHNICAL SPECIFICATIONS 2013

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MUNICIPAL CORPORATION OF GREATER MUMBAI BRIDGE DEPARTMENT TECHNICAL SPECIFICATIONS 2013

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MUNICIPAL CORPORATION OF

TECHNICAL SPECIFICATIONS FOR

Municipal Corporation of Greater Mumbai

Municipal Corporation of Greater Mumbai

A.M.C. (Project) Municipal Commissioner

Municipal Corporation of Greater Mumbai

SP-BW CLAUSE TITLE PAGE NO.

1000 MATERIAL FOR STRUCTURES ............................................................................ 9

1001 GENERAL ............................................................................................................ 10

1002 SOURCES OF MATERIAL ................................................................................... 10

1003 BRICKS ................................................................................................................ 10

1004 STONES ............................................................................................................... 10

1005 CAST IRON .......................................................................................................... 11

1006 CEMENT .............................................................................................................. 11

1007 COARSE AGGREGATES ..................................................................................... 12

1008 SAND/FINE AGGREGATES ................................................................................. 13

1009 STEEL .................................................................................................................. 14

1011 TIMBER ................................................................................................................ 18

1012 CONCRETE ADMIXTURES ................................................................................. 18

1013 REINFORCED CONCRETE PIPES ...................................................................... 19

1014 STORAGE OF MATERIALS ................................................................................. 20

1015 TESTS AND STANDARD OF ACCEPTANCE ...................................................... 22

1100 PILE FOUNDATIONS ........................................................................................... 25

1101 DESCRIPTION ..................................................................................................... 26

1102 SUB-SURFACE INVESTIGATION ........................................................................ 26

1103 TYPE OF PILES ................................................................................................... 27

1104 MATERIALS ......................................................................................................... 27

1105 TEST PILES ......................................................................................................... 28

1106 PRECAST CONCRETE PILES ............................................................................. 29

1107 CAST-IN-SITU CONCRETE PILES ...................................................................... 31

1108 STEEL PILES ....................................................................................................... 34

1109 TIMBER PILES ..................................................................................................... 35

MUNICIPAL CORPORATION OF GREATER MUMBAI Page 1

1110 DRIVING EQUIPMENT ......................................................................................... 35

1112 RAKER (INCLINED) PILES .................................................................................. 40

1113 PILE TESTS ......................................................................................................... 40

1114 PILE CAP ............................................................................................................. 41

1115 IMPORTANT CONSIDERATIONS, INSPECTION/PRECAUTIONS FOR

1116 TOLERANCES ..................................................................................................... 44

1117 TESTS AND STANDARDS OF ACCEPTANCE .................................................... 45

1118 MEASUREMENTS FOR PAYMENT ..................................................................... 45

1200 WELL FOUNDATIONS ......................................................................................... 46

1201 DESCRIPTION ..................................................................................................... 47

1202 GENERAL ............................................................................................................ 47

1203 SETTING OUT AND PREPARATIONS FOR SINKING ......................................... 48

1204 CUTTING EDGE ................................................................................................... 51

1205 Well CURB............................................................................................................ 51

1206 WELL STEINING .................................................................................................. 51

1207 WELL SINKING .................................................................................................... 52

1208 BOTTOM PLUG .................................................................................................... 62

1209 SAND FILLING ..................................................................................................... 63

1210 TOP PLUG ........................................................................................................... 63

1211 WELL CAP ........................................................................................................... 63

1212 TOLERANCES ..................................................................................................... 64

1213 TESTS AND STANDARDS OF ACCEPTANCE .................................................... 64

1214 MEASUREMENTS FOR PAYMENT ..................................................................... 64

1215 RATE .................................................................................................................... 65

1300 BRICK MASONRY ................................................................................................ 67

1301 DESCRIPTION ..................................................................................................... 68

MUNICIPAL CORPORATION OF GREATER MUMBAI Page 2

1302 MATERIALS ......................................................................................................... 68

1304 CEMENT MORTAR .............................................................................................. 68

1305 SOAKING OF BRICKS ......................................................................................... 69